D65EX D65PX: Operation & Maintenance Manual

Operation & EEAM024400
Maintenance Manual
D65EX-15E0
D65PX-15E0
BULLDOZER
SERIAL NUMBER
D65EX-15E0 - 69001 and up
D65PX-15E0 - 69001 and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
11
BEFORE READING THIS MANUAL FOREWORD
BEFORE READING THIS MANUAL 1

This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this
manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event
should you or others engage in the prohibited uses or actions described in this manual. Improper operation and
maintenance of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant person-
nel can read it at any time.
Operation and Maintenance Manual Storing Place
For a machine with a cab, a pocket is provided on the inside of

both right and left doors.
For a machine with a ROPS canopy, a pocket is provided at the

end of the floor.
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR (1-13)“.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
1-2
FOREWORD BEFORE READING THIS MANUAL
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to addi-
tional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
q The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has
been shipped. If this machine has been purchased in another country, it may lack certain safety devices and spec-
ifications that are necessary for use in your country. If there is any question about whether your product complies
with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
1-3
IMPORTANT SAFETY INFORMATION FOREWORD
IMPORTANT SAFETY INFORMATION 1

To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The “Safety Alert Symbol“ identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
DANGER result in death or serious injury
This signal word indicates a potentially hazardous situation which, if not avoided,
WARNING could result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not
CAUTION avoided, may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced if
NOTICE the precaution is not followed.
REMARKS This word is used for information that is useful to know.
1-4
FOREWORD IMPORTANT SAFETY INFORMATION
Noise emission levels 1

Two labels indicating the machine noise level are affixed on the
machine.
q Sound pressure level at the operator's station, measured

according to ISO6396 (Dynamic test method, simulated
working cycle)
q Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
q If equipped with air suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
q If equipped with mechanical suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s².
D65EX-15 : the actual acceleration value for the body is 0.63 m/s².
D65EXL-15, D65PX-15 : the actual acceleration value for the body is 0.68 m/s².
1-5
IMPORTANT SAFETY INFORMATION FOREWORD
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine 1

The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual

q Tire pressures (for wheeled machines), tension of crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of traveling path as large as possible
q Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling

q Reduce speed to prevent bounce
q Transport machines long distances between worksites
1-6
FOREWORD IMPORTANT SAFETY INFORMATION
8. The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good health.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads.
1-7
INTENDED USE FOREWORD
INTENDED USE 1
USE OF MACHINE 1
This Komatsu machine is designed to be used mainly for the following work:
q Dozing
q Smoothing
q Cutting into hard or frozen ground or ditching
q Felling trees, removing stumps
See the section “WORK POSSIBLE USING BULLDOZER (3-88)“ for further details.
GENERAL VIEW AND DIRECTIONS OF MACHINE 1
In this manual, the directions of the machine (front,rear,left,right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
(1) Blade (7) Sprocket

(2) Tilt cylinder (8) Track frame
(3) Lift cylinder (9) Step
(4) Cab (10) Frame
(5) ROPS guard (11) Idler
(6) Track shoe (12) ROPS canopy
(A) Front (C) Left

(B) Rear (D) Right
1-8
FOREWORD INTENDED USE
VISIBILITY FROM OPERATOR'S SEAT 1

The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY 1
The figure bellows shows a front visibility from the machine at a spot 1.0 m away from the side and 1.5 m above
the ground. Shaded area (A) in the figure shows an area whose view is blocked by part of the machine. Operate
the machine, fully aware that the machine has a portion that an operator cannot see.
12M CIRCUMFERENCE VISIBILITY 1

The figure below shows a visibility from the machine within a circle of 12 m in radius. Shaded area (B) in the figure
shows an area whose view is blocked by part of the machine. Operate the machine, fully aware that the machine
has a portion that an operator cannot see.
1-9
INTENDED USE FOREWORD
BREAKING-IN THE NEW MACHINE 1

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking the machine in can adversely affect the perfor-
mance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
q Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
1-10
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO.

AND DISTRIBUTOR 1
When ordering replacement parts, please inform your Komatsu distributor of the following.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1

This is at the front bottom right of the operator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE POSITION 1

The engine serial No. plate is located on the side of the engine front cover on the left side of the machine.
1-11
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
ADDITIONAL EPA NAMEPLATE 1

The additional EPA nameplate is located on top of the engine head cover on the left side of the machine.
EPA: Environmental Protection Agency, U.S.A.
SERVICE METER POSITION 1

The service meter is provided at the lower part of the monitor
panel.
1-12
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number

(PIN)
Manufacturers name: KOMATSU LTD.

Address: 3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
Distributor
Address
Phone
Service personnel for your

machine:
1-13
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
MACHINE SERIAL NUMBER PLATE 1
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer
1-14
CONTENTS
CONTENTS
FOREWORD
BEFORE READING THIS MANUAL.................................................................................................................... 1-2
IMPORTANT SAFETY INFORMATION ............................................................................................................... 1-4

Noise emission levels ................................................................................................................................. 1-5
Vibration levels............................................................................................................................................ 1-5
Guide to Reduce Vibration Levels on Machine.................................................................................. 1-6
INTENDED USE ................................................................................................................................................... 1-8

USE OF MACHINE ..................................................................................................................................... 1-8
GENERAL VIEW AND DIRECTIONS OF MACHINE ................................................................................. 1-8
VISIBILITY FROM OPERATOR'S SEAT.................................................................................................... 1-9
PROXIMITY VISIBILITY .................................................................................................................... 1-9
12M CIRCUMFERENCE VISIBILITY ................................................................................................ 1-9
BREAKING-IN THE NEW MACHINE ....................................................................................................... 1-10
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ........................................... 1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ..................................... 1-11
ENGINE SERIAL NO. PLATE POSITION ................................................................................................ 1-11
ADDITIONAL EPA NAMEPLATE ............................................................................................................. 1-12
SERVICE METER POSITION .................................................................................................................. 1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-13
MACHINE SERIAL NUMBER PLATE....................................................................................................... 1-14
SAFETY
IMPORTANT SAFETY INFORMATION ............................................................................................................... 2-2
SAFETY LABELS................................................................................................................................................. 2-4

POSITION FOR ATTACHING SAFETY LABELS....................................................................................... 2-5
SAFETY LABELS ....................................................................................................................................... 2-5
PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ............................................................... 2-10
PRECAUTIONS DURING OPERATION ............................................................................................................ 2-17
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-23
PRECAUTIONS FOR MACHINE........................................................................................................................ 2-29
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
1-15
CONTENTS
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-6

FRONT PANEL ........................................................................................................................................... 3-6
CHECK MONITOR SYSTEM ............................................................................................................ 3-7
EMERGENCY CAUTION ITEMS ...................................................................................................... 3-8
CAUTION ITEMS............................................................................................................................. 3-10
METER GROUP .............................................................................................................................. 3-12
LAMPS............................................................................................................................................. 3-16
SWITCHES ...................................................................................................................................... 3-18
METHOD OF USING MAINTENANCE MODE ................................................................................ 3-22
SWITCHES ............................................................................................................................................... 3-29
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-33
CIRCUIT BREAKER ................................................................................................................................. 3-41
FUSE ........................................................................................................................................................ 3-41
FUSIBLE LINK .......................................................................................................................................... 3-43
ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-43
MACHINE EQUIPPED WITH CAB .................................................................................................. 3-43
MACHINE EQUIPPED WITH ROPS CANOPY ............................................................................... 3-44
DOOR - OPEN LOCK ............................................................................................................................... 3-44
SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-45
DOOR POCKET ....................................................................................................................................... 3-45
OPENING AND CLOSING ENGINE SIDE COVER.................................................................................. 3-46
ASHTRAY ................................................................................................................................................. 3-46
CUP HOLDER .......................................................................................................................................... 3-47
TOOL BOX................................................................................................................................................ 3-47
SHOVEL HOLDER ................................................................................................................................... 3-47
AIR CONDITIONER, HANDLING ............................................................................................................. 3-48
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................................................ 3-48
METHOD OF OPERATION ............................................................................................................. 3-50
PRECAUTIONS WHEN USING ...................................................................................................... 3-51
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE .......... 3-51
INSPECTION DURING OFF-SEASON ........................................................................................... 3-51
PROCEDURE FOR REPLACING RECEIVER ................................................................................ 3-51
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-52
CLEANING AIR FILTER .................................................................................................................. 3-52
OPERATION ....................................................................................................................................................... 3-53

CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-53
WALK-AROUND CHECK ................................................................................................................ 3-53
CHECK BEFORE STARTING ......................................................................................................... 3-54
ADJUSTMENT................................................................................................................................. 3-62
OPERATION AND CHECK BEFORE STARTING ENGINE............................................................ 3-66
STARTING ENGINE ................................................................................................................................. 3-68
NORMAL STARTING ...................................................................................................................... 3-68
STARTING IN COLD WEATHER .................................................................................................... 3-70
OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................................................... 3-73
WARMING UP OPERATIONS ........................................................................................................ 3-73
1-16
CONTENTS
STARTING IN COLD WEATHER .................................................................................................... 3-74

STOPPING ENGINE................................................................................................................................. 3-75
MACHINE OPERATION ........................................................................................................................... 3-77
MOVING MACHINE......................................................................................................................... 3-77
STOPPING MACHINE..................................................................................................................... 3-79
SHIFTING GEARS.................................................................................................................................... 3-79
GEARSHIFTING OPERATION........................................................................................................ 3-80
GEARSHIFTING OPERATION USING PRESET MODE FUNCTION ............................................ 3-80
AUTO DOWN SHIFT OPERATION................................................................................................. 3-82
SHIFTING BETWEEN FORWARD AND REVERSE ................................................................................ 3-83
STEERING MACHINE .............................................................................................................................. 3-85
NORMAL TURNING ........................................................................................................................ 3-85
PRECAUTIONS FOR OPERATION ......................................................................................................... 3-86
PAY ATTENTION TO GAUGES...................................................................................................... 3-86
PERMISSIBLE WATER DEPTH...................................................................................................... 3-86
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................................................... 3-86
PRECAUTIONS ON SLOPES ......................................................................................................... 3-87
METHOD OF USING BRAKES ....................................................................................................... 3-87
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................... 3-87
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-87
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES.................. 3-88
WORK POSSIBLE USING BULLDOZER ................................................................................................. 3-88
DOZING........................................................................................................................................... 3-88
SMOOTHING................................................................................................................................... 3-89
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING .................................................... 3-89
FELLING TREES, REMOVING STUMPS ....................................................................................... 3-89
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................... 3-90
ADJUST ANGLE OF BLADE EDGE................................................................................................ 3-90
ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT ........................................................ 3-91
ADJUSTING TENSION OF CENTER BRACE ................................................................................ 3-91
ADJUST AMOUNT OF TILT............................................................................................................ 3-92
METHOD OF ANGLING BLADE ..................................................................................................... 3-93
PARKING MACHINE ................................................................................................................................ 3-94
CHECK AFTER FINISHING WORK ......................................................................................................... 3-95
BEFORE STOPPING ENGINE........................................................................................................ 3-95
AFTER STOPPING ENGINE........................................................................................................... 3-95
LOCKING.................................................................................................................................................. 3-96
TIPS FOR LONGER UNDERCARRIAGE LIFE ........................................................................................ 3-96
OPERATION METHOD ................................................................................................................... 3-96
INSPECTION AND ADJUSTMENT ................................................................................................. 3-97
INSPECTION AND REPAIR............................................................................................................ 3-97
TRANSPORTATION......................................................................................................................................... 3-100
TRANSPORTATION MEANS ................................................................................................................. 3-100
REMOVING CAB .................................................................................................................................... 3-100
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-100
PRECAUTIONS WHEN REMOVING ROPS .......................................................................................... 3-101
1-17
CONTENTS
LOADING, UNLOADING WORK ............................................................................................................ 3-102

LIFTING MACHINE................................................................................................................................. 3-105
TRAVELING ON ROADS ....................................................................................................................... 3-107
COLD WEATHER OPERATION ...................................................................................................................... 3-108

PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-108
AFTER COMPLETION OF WORK ......................................................................................................... 3-109
AFTER COLD WEATHER ...................................................................................................................... 3-109
LONG-TERM STORAGE.................................................................................................................................. 3-110

BEFORE STORAGE............................................................................................................................... 3-110
DURING STORAGE ............................................................................................................................... 3-110
AFTER STORAGE.................................................................................................................................. 3-110
TROUBLESHOOTING...................................................................................................................................... 3-111
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-111
PROCEDURE FOR BLEEDING AIR ............................................................................................. 3-111
METHOD OF TOWING MACHINE ......................................................................................................... 3-112
IF BATTERY IS DISCHARGED .............................................................................................................. 3-113
REMOVE AND INSTALL BATTERY ............................................................................................. 3-114
PRECAUTIONS FOR BATTERY CHARGING .............................................................................. 3-114
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-115
OTHER TROUBLE ................................................................................................................................. 3-117
ELECTRICAL SYSTEM ................................................................................................................. 3-117
MONITOR PANEL ......................................................................................................................... 3-118
CHASSIS ....................................................................................................................................... 3-119
ENGINE ......................................................................................................................................... 3-121
MAINTENANCE
GUIDE TO MAINTENANCE ................................................................................................................................. 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................................... 4-5
OIL ..................................................................................................................................................... 4-5
FUEL.................................................................................................................................................. 4-6
COOLANT AND WATER FOR DILUTION......................................................................................... 4-6
GREASE ............................................................................................................................................ 4-7
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-7
STORING OIL AND FUEL ................................................................................................................. 4-8
FILTERS ............................................................................................................................................ 4-8
RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-8
HANDLING HYDRAULIC SYSTEM ............................................................................................................ 4-9
WEAR PARTS LIST ........................................................................................................................................... 4-10

WEAR PARTS LIST.................................................................................................................................. 4-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-12
1-18
CONTENTS
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ............ 4-13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........................................................................................................................................... 4-15
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-16

TORQUE LIST .......................................................................................................................................... 4-16
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-17

SAFETY CRITICAL PARTS...................................................................................................................... 4-17
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-19

MAINTENANCE SCHEDULE CHART...................................................................................................... 4-19
WHEN REQUIRED.......................................................................................................................... 4-19
CHECK BEFORE STARTING ......................................................................................................... 4-19
EVERY 50 HOURS SERVICE......................................................................................................... 4-19
EVERY 250 HOURS SERVICE....................................................................................................... 4-19
EVERY 500 HOURS SERVICE....................................................................................................... 4-19
EVERY 1000 HOURS SERVICE..................................................................................................... 4-19
SERVICE PROCEDURE .................................................................................................................................... 4-21

WHEN REQUIRED ................................................................................................................................... 4-21
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-21
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-24
CHECK TRACK SHOE TENSION, ADJUST................................................................................... 4-27
CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-29
REVERSE AND REPLACE END BITS AND CUTTING EDGES .................................................... 4-30
CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND AFTER-
COOLER.......................................................................................................................................... 4-32
CHECK, ADJUST AIR CONDITIONER ........................................................................................... 4-35
GREASE DOOR HINGE.................................................................................................................. 4-36
CHECK DOOR LOCK STRIKER ..................................................................................................... 4-37
REPLACE DOOR DAMPER............................................................................................................ 4-37
CHECK DOOR LATCH.................................................................................................................... 4-37
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .............................................................. 4-38
REPLACE WIPER BLADE .............................................................................................................. 4-39
CHECK IDLER OIL LEVEL, ADD OIL ............................................................................................. 4-40
ADJUST IDLER CLEARANCE ........................................................................................................ 4-40
LUBRICATING UNIVERSAL JOINT................................................................................................ 4-41
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM..................................................... 4-42
CHECK BEFORE STARTING .................................................................................................................. 4-43
EVERY 50 HOURS SERVICE .................................................................................................................. 4-43
DRAIN WATER, SEDIMENT FROM FUEL TANK........................................................................... 4-43
EVERY 250 HOURS SERVICE ................................................................................................................ 4-44
LUBRICATING................................................................................................................................. 4-44
GREASE EQUALIZER BAR SIDE PIN............................................................................................ 4-45
GREASE EQUALIZER BAR CENTER PIN ..................................................................................... 4-46
1-19
CONTENTS
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-46
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL .................................................................... 4-47
CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-48
CHECK, CLEAN ADDITIONAL FUEL STRAINER .......................................................................... 4-49
CHECK BRAKE PERFORMANCE .................................................................................................. 4-50
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)............................................ 4-51
EVERY 500 HOURS SERVICE ................................................................................................................ 4-52
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE .................... 4-52
REPLACE POWER TRAIN OIL FILTER ELEMENT........................................................................ 4-54
REPLACE FUEL PRE-FILTER CARTRIDGE.................................................................................. 4-54
EVERY 1000 HOURS SERVICE .............................................................................................................. 4-57
REPLACE FUEL MAIN FILTER CARTRIDGE ................................................................................ 4-57
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP STRAINER,
SCAVENGING PUMP STRAINER) ................................................................................................. 4-60
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ......................................................................... 4-62
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................ 4-63
CLEAN BREATHER ........................................................................................................................ 4-63
REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-64
CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................ 4-64
INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS .................. 4-64
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT..................................... 4-65
REPLACE HYDRAULIC TANK BREATHER ELEMENT ................................................................. 4-66
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT) ......................................................................................................................................... 4-66
CHANGE OIL IN DAMPER CASE ................................................................................................... 4-69
CHECK VIBRATION DAMPER ....................................................................................................... 4-70
CHECK ENGINE VALVE CLEARANCE, ADJUST .......................................................................... 4-70
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) .............................................................. 4-71
CHECK WATER PUMP ................................................................................................................... 4-71
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER ...... 4-72
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER ....... 4-73
REPLACE HIGH-PRESSURE PIPING CLAMP .............................................................................. 4-74
REPLACE FUEL SPLAY PREVENTION CAPS .............................................................................. 4-74
SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ................................................................................................... 6-2
1-20
CONTENTS
HANDLING HYDRAULIC RIPPER....................................................................................................................... 6-3

GENERAL VIEW......................................................................................................................................... 6-3
EXPLANATION OF COMPONENTS .......................................................................................................... 6-4
OPERATION............................................................................................................................................... 6-5
CHECK BEFORE STARTING ENGINE, ADJUST ............................................................................ 6-5
PRECAUTIONS WHEN OPERATING............................................................................................... 6-5
ADJUSTING POSTURE OF WORK EQUIPMENT ........................................................................... 6-5
TROUBLESHOOTING................................................................................................................................ 6-7
OTHER TROUBLE ............................................................................................................................ 6-7
MAINTENANCE.......................................................................................................................................... 6-7
EVERY 250 HOURS SERVICE......................................................................................................... 6-7
SPECIFICATIONS ...................................................................................................................................... 6-8
AIR SUSPENSION SEAT..................................................................................................................................... 6-9
DELUXE SEAT ................................................................................................................................................... 6-12
HEADREST ........................................................................................................................................................ 6-14
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT................................................................................. 6-15
INDEX
COLOPHON
1-21
CONTENTS
1-22
SAFETY
12
WARNING
Please read and make sure that you fully understand the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.
IMPORTANT SAFETY INFORMATION SAFETY
IMPORTANT SAFETY INFORMATION 2

SAFETY LABELS................................................................................................................................................ 2-42
POSITION FOR ATTACHING SAFETY LABELS .............................................................................................. 2-52
SAFETY LABELS............................................................................................................................................... 2-52
PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE............................................................... 2-102

FOR SAFE OPERATION ................................................................................................................................. 2-102
KNOW YOUR EQUIPMENT ............................................................................................................................ 2-102
PREPARE FOR SAFE OPERATION ............................................................................................................... 2-102
CLOTHING AND PERSONAL PROTECTIVE ITEMS ..................................................................................... 2-112
FIRE EXTINGUISHER AND FIRST AID KIT ................................................................................................... 2-112
KEEP THE MACHINE CLEAN ......................................................................................................................... 2-112
IF ABNORMALITIES ARE FOUND.................................................................................................................. 2-112
HANDRAILS AND STEPS ............................................................................................................................... 2-122
MOUNTING AND DISMOUNTING .................................................................................................................. 2-122
INSIDE OPERATOR'S COMPARTMENT........................................................................................................ 2-122
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT ........................................................... 2-132
PRECAUTIONS WHEN LEAVING THE MACHINE ......................................................................................... 2-132
EMERGENCY ESCAPE FROM OPERATOR'S CAB ...................................................................................... 2-132
FIRE PREVENTION......................................................................................................................................... 2-142
ACTION IF FIRE OCCURS.............................................................................................................................. 2-152
BATTERY HAZARD PREVENTION ................................................................................................................ 2-152
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS .............................................................. 2-162
BE CAREFUL ABOUT ASBESTOS DUST ...................................................................................................... 2-162
PRECAUTIONS DURING OPERATION ........................................................................................................... 2-172

EXAMINATION AND CONFIRMATION OF WORKSITE ................................................................................. 2-172
WORKING ON LOOSE GROUND ................................................................................................................... 2-172
DO NOT GO NEAR HIGH-VOLTAGE CABLES .............................................................................................. 2-172
ENSURE GOOD VISIBILTY ............................................................................................................................ 2-182
CONFIRMATION OF MARK ............................................................................................................................ 2-182
PRECAUTION FOR WARNING TAG .............................................................................................................. 2-182
CHECK BEFORE STARTING ENGINE,ADJUST ............................................................................................ 2-182
PRECAUTIONS WHEN STARTING ................................................................................................................ 2-192
STARTING WITH BOOSTER CABLES ........................................................................................................... 2-192
CHECK BEFORE STARTING OPERATION ................................................................................................... 2-202
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE ............................................................. 2-202
PRECAUTIONS WHEN TRAVELING .............................................................................................................. 2-212
PRECAUTIONS FOR ACCUMULATED SNOW, AND ICE.............................................................................. 2-212
SHIPPING ........................................................................................................................................................ 2-212
WHEN TOWING .............................................................................................................................................. 2-222
PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-232

UNAUTHORIZED MODIFICATION ................................................................................................................. 2-232
WARNING TAG ............................................................................................................................................... 2-232
KEEP WORK PLACE FOR MAINTENANCE CLEAN AND TIDY .................................................................... 2-232
REPAIR WELDING .......................................................................................................................................... 2-232
USE CAUTION WHEN FUELING .................................................................................................................... 2-232
PERSONAL MAINTENANCE .......................................................................................................................... 2-232
PROPER TOOLS............................................................................................................................................. 2-242
SELECTION WORK PLACE FOR MAINTENANCE ........................................................................................ 2-242
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.......................................... 2-242
TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING ......................... 2-252
WORK UNDER THE MACHINE ...................................................................................................................... 2-252
PRECAUTIONS WHEN USING HAMMER ...................................................................................................... 2-262
2-2
SAFETY IMPORTANT SAFETY INFORMATION
PREVENTION BURNS FROM HOT WATER .................................................................................................. 2-262

PREVENTION BURNS FROM HOT OIL ......................................................................................................... 2-262
COMPRESSED AIR......................................................................................................................................... 2-262
HANDLING HIGH-PRESSURE HOSES, PIPING............................................................................................ 2-262
PRECAUTIONS WITH HIGH-PRESSURE OIL ............................................................................................... 2-272
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION..................... 2-272
DO NOT DISASSEMBLE RECOIL SPRING.................................................................................................... 2-272
ACCUMULATOR ............................................................................................................................................. 2-282
MAINTENANCE OF AIR CONDITIONER........................................................................................................ 2-282
WASTE MATERIALS ....................................................................................................................................... 2-282
PRECAUTIONS FOR MACHINE ...................................................................................................................... 2-292

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)......................................................... 2-292
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
The following safety labels are used on this machine.
q Make sure that you fully understand the location and content of each safety label, together with the means of
avoiding the danger shown.
q To ensure that the contents of safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning the labels, do not use organic solvents or gasoline. They may cause
the labels to peel off.
q If the labels are damaged, lost, or cannot be read properly, contact your Komatsu distributor immediately
regarding their replacement. For details concerning the part numbers for the labels, see this manual or the
actual label.
q There are also other labels on the machine in addition to the safety labels. Handle those labels in the same
way.
2-4
SAFETY SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS 2
SAFETY LABELS 2
(1) Caution before operating or maintaining machine
(09651-A0641)
q Warning!
q Read manual before operation, maintaince, disassembly,

assembly and transportation.
2-5
(2) Caution before moving in reverse (09802-B0750)
(3) Caution for leaving operator's seat (09654-B0641)
q Sign indicates a hazard of unexpected moving of stopped

machine.
q Lower working device to ground, move safety lever to lock

position and take engine key with you before leaving
machine.
(4) Caution with high-temperature coolant, hydraulic oil
(09653-A0481)
q Never remove the cap when the engine is at operating

(high) temperature. Stream or high temperature oil blowing
up from the radiator or hydraulic tank, will cause personal
injury and / or burns.
q Never remove the radiator or hydraulic tank oil filler when

cooling water or hydraulic oil is at high temperatures.
2-6
(5) Caution for accumulator (09659-A057B)
q There is the hazard of explotion causing injury.
q Do not disassemble the accumulator, make holes in it, weld

it, cut it, hit it, roll it or bring it near flame.
(6) Caution for adjusting track tension (09657-A0881)
The safety label is attached to the rear side of the track adjust-
ment window cover.
q Sign indicates a hazzard of flying plug from track adjuster

that could cause injury.
q Read the manual and adjusting track for safe and proper
handling.
(7) Caution for battery cable (09808-A0881)
q Sign indicates an electric hazzard from handling the cable.
q Read the operation and maintenance manual and carrying

out the correct method when handling.
(8) Stop rotation during inspection and maintenance
(09667-A0481)
q Sign indicates a hazard of rotating parts, such as belt.
q Turn off before inspection and maintenance.
2-7
(9) Caution for approach when machine moving
(09806-B1201)
q Sign indicates a hazard of being run over by moving equip-

ment.
q Keep a safe distance from equipment when it is moving.
(10) Prohibition of jump start (09842-A0481)
q Start the engine only after sitting down in the operator’s

seat.
q Do not attempt to start the engine by short-circuiting the

engine starting circuit. Such an act may cause a serious
bodily injury or fire.
(11) Caution for ROPS (09620-B2000)
ROPS CERTIFICATION
This protective structure complies with the standard provided that is properly equipped on the machine which
mass is less than the specified maximum mass.
1. MODEL 3. FOPS LEVEL No. 5. MAX. MASS kg (Lb)

2. MACHINE MODEL 4. SERIAL NO.
WARNING
q If some modification is applied to the ROPS. It might not enough strength and might not be complied with the
standard. Consult Komatsu Distributor before altering.
q ROPS may provide less protection if it has been structurally damaged or involved roll-over. Consult Komatsu
Distributor in that case.
Always wear seat belt when moving.
2-8
(12) Caution for FOPS (09620-C2000)
FOPS CERTIFICATION
This protective structure was provided to comply with the following standard.
1. MODEL 2. MACHINE MODEL

3. SERIAL NO. 4. FOPS LEVEL No.
q If some modification is applied to the FOBS. It might not enough strength and might not be complied with the
standard. Consult Komatsu Distributor before altering.
q FOBS may provide less protection if it has been structurally damaged or involved roll-over. Consult Komatsu
Distributor in that case.
q Always wear seat belt when moving.
2-9
PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY
PRECAUTIONS COMMON TO OPERATION AND MAINTE-

NANCE 2
Improper operation and maintenance can cause serious injury or death. Read the manual and safety labels
before operating or servicing the machine. Follow all warnings and instructions.
FOR SAFE OPERATION
For safe operation of this machine, you must be a qualified and authorized operator. To be qualified, you must
understand the written instructions supplied by the manufacturer, have training including actual operation of this
machine and know the safety rules and regulations for the job site.
On the job, an operator must not use drugs or alcohol which can impair his alertness or coordination. An operator
on prescription or over-the-counter drugs needs medical advice regarding whether or not he/she can safely oper-
ate the machine.
KNOW YOUR EQUIPMENT
Know your machine. Know how to operate all equipment on your machine. Know the purpose of the controls,
gauges and indicators. Know the rated load capacity, speed range, braking and steering characteristics, turning
radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, etc. change the oper-
ating capabilities of your machine.
Study the Manual before starting the machine. If there is something in the Manual you do not understand, ask your
supervisor to explain it to you.
PREPARE FOR SAFE OPERATION
q Check the Safety Equipment
To protect you and others around you, your machine may be equipped with the following safety equipment.
See that each item is securely in place and in operating condition.
q Rollover Protection
q Falling Object Protection
q Lights
q Horn
q Mirrors
q Windshield Wipers & Washers (machine equipped with cab)
Never remove or disconnect any safety device.
q Check the machine conditions
Before operating the machine, check the machine and make sure that it is in a good condition. Never start the
machine operation until after a defect, if any, is completely removed.
q Check the machine for any damaged and missing parts, and if necessary, make necessary repairs.
q If any of the trunnions, seals, bushings and bearings is found defective, replace it with a new one.
q Check the service brake and parking brake to see if they work normally.
q Check all the cooling systems
Before checking the radiator cooling water level, make sure that the cooling water temperature has sufficiently
cooled off.
2-10
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
CLOTHING AND PERSONAL PROTECTIVE ITEMS
To avoid the risk of injury:
q Do not wear jewelry while in operation. You may catch on the control lever or a protruding part and fall off.
q Do not wear loose clothes while in operation. You may

catch on the control lever or any other lever, causing the
machine to make an unexpected move.
q Always wear a hard hat and safety shoes. In addition,

depending on the nature of the work, wear safety glasses,
mask, ear mufflers, safety belt, or other protective equip-
ment.
q Do not let your hair extend outside your hard hat. It could
get caught in rotating parts.
FIRE EXTINGUISHER AND FIRST AID KIT
q Make sure that a fire extinguisher is provided in case of

fire. Quick extinguishing of a fire can reduce the damage to
the machine and avoid risk of personal injury.
Check the fire extinguisher periodically and make sure that

you fully understand the method of use.
q Make sure that a first aid kit is provided in case of injury. If

immediate action is taken in case of injury, the extent of the
injury can be reduced. Keep the first aid kit in the specified
place, check the contents periodically, and replace any
items that have been used or are missing.
KEEP THE MACHINE CLEAN
To avoid the risk of injury:
q If there is mud or oil stuck to the machine, you may slip and fall when getting on or off the machine, wipe off
any mud or oil stuck to the machine, and always keep the machine clean.
q If water gets into the electrical system, the electrical equip-

ment may malfunction or not work properly. If it malfunc-
tions, there is danger of the machine moving unexpectedly,
leading to serious personal injury or death. When cleaning
the machine, do not to wash the electrical system (sensors,
connectors) with water or steam.
IF ABNORMALITIES ARE FOUND
During operation, inspection or maintenance, if any abnormality is noticed (noise, vibration, smell, wrong display
by gauges, smoke, oil leakage, or abnormal displays on the gauges, warning devices or monitors), stop the
machine on flat ground and report the problem immediately to the jobsite supervisor. If the machine continues to
be operated without repairing the problem, it may lead to serious personal injury or death.
2-11
HANDRAILS AND STEPS
To avoid risk of injury when getting on or off the machine.

q When getting on or off the machine, always face the
machine and maintain three- point contact (both feet and
one hand or one foot and both hands) with the handrails,
steps (and also track shoes) to ensure that you support
yourself securely.
q Always check the handrails and steps for oil, grease, or

mud. Wipe them clean before using.
q Repair any damage and tighten any loose bolts.
q Never get on or off the machine while holding tools in your

hand.
q When getting on or off the machine, never hold any control

lever, as it can move.
MOUNTING AND DISMOUNTING
q Never jump onto the machine. There is danger that your feet will slip, and you will fall and be seriously injured.
q Never jump off the machine. There is danger that you will break a bone or suffer other serious injury when
landing.
q Never get on or off a moving machine. You may be unable to support yourself with the handrail or steps, and
fall from the machine, suffering injury. Even if the machine starts off with no operator on it, do not jump on the
machine and try to stop it.
INSIDE OPERATOR'S COMPARTMENT
q When entering the operator's compartment, always wipe off all mud and oil from the soles of your shoes. If you
try to operate the pedals with mud or oil on the soles of your shoes, your foot may slip and the machine may
move unexpectedly, causing serious personal injury to yourself or others.
q Do not leave tools or a machine parts lying around inside the operator's compartment. If tools or parts get into
the equipment, it may obstruct operation and cause the machine to move unexpectedly, resulting in serious
personal injury.
q Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
q Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could serious personal injury to yourself or others.
2-12
q Do not bring any dangerous items, such as explosives or items that may ignite, into the operator's compart-
ment.
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT
When standing up from the operator's seat, always lower the

work equipment to the ground, operate work equipment lock
lever (1) and parking brake lever (2) to the LOCK (L) position
and stop the engine.
If you accidentally touch any of the work equipment levers

when it is not securely locked, the machine may suddenly
move and cause a serious injury or death.
PRECAUTIONS WHEN LEAVING THE MACHINE
If the correct procedures are not followed when stopping the machine, the machine may suddenly move off with no
operator on it. This may lead to serious personal injury. Always observe the following precautions strictly.
q Before leaving the operator's compartment, lower the work
equipment to the ground, operate work equipment lock
lever (1) and parking brake lever (2) to the LOCK (L) posi-
tion and then stop the engine.
q Remove the key from the starting switch.
q Lock all the doors of the operator's compartment.
q Take the key with you and leave it in the specified place.
EMERGENCY ESCAPE FROM OPERATOR'S CAB
There are doors on the left and right sides of the operator's compartment. If the door on one side will not open,
escape through the door on the opposite side. If you do not escape quickly during an emergency, you may suffer
serious injury.
2-13
FIRE PREVENTION
q Fire coming from fuel, oil, antifreeze, window washer

fluid
Fuel, oil, antifreeze, and window washer fluid will ignite if

brought close to a flame, so there is danger of fire. Always
obey the following.
q Do not smoke or use any flame near fuel, oil, anti-

freeze, or window washer fluid.
q Always stop the engine before adding fuel or oil.
q When adding fuel, oil, antifreeze, or window washer

fluid, stay in the area and observe carefully that noth-
ing is spilled.
q After adding fuel or oil, tighten all the caps securely to

prevent the fuel or oil from flowing out.
q Do not spill oil on hot surfaces or components of the

electrical system.
q After adding fuel or oil, wipe up any spilled fuel or oil

with a cloth.
q Put fuel-soaked or oily cloths and other flammable

materials in the specified container and keep the con-
tainer in a place where there is no danger of the con-
tents igniting.
q Use non-flammable flushing oil when washing parts.

Do not use fuel or gasoline or any other fluid that may
ignite.
q Do not weld or use a gas cutter on pipes or tubes con-

taining flammable fluids.
q Store fuel and oil in a place where there is good venti-

lation.
q Store fuel and oil in the specified place, do not store

more than the specified storage limit, and do not let
any unauthorized person enter the area.
q When carrying out grinder operations or welding oper-

ations on the machine, move any flammable sub-
stances to a place where there is no danger of them
igniting.
q Fire coming from accumulated or spilled flammable substances
Remove dry leaves, wood chips, paper, or other flammable substances that may accumulate on the engine
compartment.
q Fire coming from electric wiring
q Clean all the electric wiring connectors and tighten the connections securely.
q Check starting that there are no loose or damaged electric wires and tighten any loose connectors or wir-
ing clamps.
q Repair or replace any damage wiring.
2-14
q Fire coming from hydraulic line
Fix the cushions of the piping, guards, tubes, and hoses securely.
q Explosion caused by lighting equipment
Use explosion-proof lighting equipment when inspecting the fuel, oil, battery fluid, window washer fluid, or
coolant. When using the machine as the power source for the lighting equipment, see “CIGARETTE LIGHTER
(3-32)“.
ACTION IF FIRE OCCURS
q Turn the starting switch OFF, stop the engine, and remove the key.
q Leave the operator's compartment through the door in the direction of safety, and use the handrail and steps to
escape from the machine.
q Do not jump off the machine. There is the danger of falling and suffering serious injury.
BATTERY HAZARD PREVENTION
q Danger of battery exploding
When the battery is being charged, flammable hydrogen

gas is generated from the poles. If the gas ignites, it may
explode and cause serious injury or fire. Therefore:
q Do not use or charge the battery if the battery electro-

lyte is below the LOWER LEVEL mark. Always carry
out periodic inspection of the battery electrolyte level,
and add distilled water to the UPPER LEVEL mark.
q Do not smoke or bring any flame close to the battery.
q Remove the battery from the machine, take it to a well-

ventilated place, remove the battery caps, then carry
out the charging. After charging, tighten the battery
caps securely.
q Danger from dilute sulphuric acid
The battery electrolyte includes dilute sulphuric acid. If

dilute sulphuric acid gets on your skin or in your eyes, you
may suffer serious injury. When handling the battery,
always do as follows.
q When handling the battery, always wear safety glasses

and rubber gloves.
q If battery electrolyte gets into your eyes, immediately

wash your eyes with large amounts of fresh water for
at least 15 minutes, and be sure to wash behind your
eyelids. After that, get medical attention immediately.
q If battery electrolyte gets on your skin or clothes, wash

it off immediately with large amounts of water. When
doing this, do not use any alkaline fluid as a neutral-
izer. If you suffer any chemical burn, get medical atten-
tion immediately.
2-15
q Danger of sparks
If sparks are generated, they may fly and cause serious personal injury. Always obey the following.
q Do not short-circuit the battery terminals through contact with metallic objects, such as tools, across the
terminals.
q Do not leave tools lying around.
q When removing the battery terminals, remove the ground terminal (negative (-) terminal) first, then remove
the positive (+) terminal.
q When installing, install the positive (+) terminal first, then install the ground terminal.
q Tighten the battery terminals securely.
q Secure the battery firmly in the specified position.
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS
The engine exhaust gas contains substances that may damage

your health or even cause death. Start or operate the engine in
a place where there is good ventilation. If the engine or
machine must be operated inside a building or under ground,
where the ventilation is poor, take steps to ensure that the
engine exhaust gas is removed and that ample fresh air is
brought in.
BE CAREFUL ABOUT ASBESTOS DUST
If you breathe in air containing asbestos dust, there is danger

that that you contract lung cancer or mesothelioma. Inhaled
asbestos dust does not cause these diseases immediately, but
it usually takes ten- odd years for the symptom to appear. Just
for that reason, you have to be cautious particularly about
asbestos. In the building demolition work or industrial wastes
disposal work, keep to the rules and regulations that provide for
working conditions in such workplaces. If you use non- genuine
parts, there is a risk that they contain asbestos, so use only
Komatsu genuine parts. This machine does use any parts that
contain asbestos.
2-16
SAFETY PRECAUTIONS DURING OPERATION
PRECAUTIONS DURING OPERATION 2

EXAMINATION AND CONFIRMATION OF WORKSITE
Before starting operations, check first if there is any danger on the jobsite. If you do not understand the dangers of
the jobsite before starting operations, the machine may tip over, or the ground may collapse, or rocks may fall,
causing injury to the operator. Always:
q Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not operate where there is a hazard of landslides or falling rocks.
q Prevent any unauthorized person from entering the operating area.
q Before operating in shallow water or on soft ground, check the depth of the water, speed of the current, and
the firmness and shape of the ground. Avoid any area where there is any obstruction to travel operations.
q Maintain the travel path on the jobsite so that there is no obstruction to travel operations.
WORKING ON LOOSE GROUND
q Do not operate close to cliffs, road shoulders, or deep ditches where the ground may be soft. There is danger
that the ground may collapse under the weight or vibration of the machine, causing the machine to tip over or
fall, and resulting in injury to the operator. In particular, be careful when carrying out operations after rain, after
explosives have been used, after earthquakes, or in other cases where the ground may easily collapse.
q The ground on embankments or close to ditches may collapse under the weight or vibration of the machine,
causing the machine to tip over or fall, and resulting in injury to the operator. Take action to ensure that the
ground is safe before starting operations.
DO NOT GO NEAR HIGH-VOLTAGE CABLES
Electrocution can result from contacting or approaching underground or overhead power cables. Never approach
overhead power lines with any part of your machine. Use extreme caution.
q Before starting work in the vicinity of electric cables, inform the local power company of the work to be per-
formed, and ask them to take the necessary steps to ensure safety.
q Know your margin of safety. If possible, have power to the

lines disconnected. If not possible, request a signal person Voltage of Cables Safety Distance
for guidance to maintain at least minimum distance 100V - 200V Over 2 m
required by law from the overhead lines. 6,600V Over 2 m
q To prepare for any possible emergencies, wear rubber 22,000V Over 3 m
shoes and gloves. Lay a rubber sheet on top of the seat, 66,000V Over 4 m
and be careful not to touch the chassis with any exposed 154,000V Over 5 m
part of your body. 187,000V Over 6 m
q When carrying out operations near high voltage cables, do 275,000V Over 7 m
not let anyone near the machine. 500,000V Over 11 m
q If the machine should come too close or touch the electric

cable, to prevent electric shock, the operator should not
leave the operator's compartment until it has been con-
firmed that the electricity has been shut off.
Also, do not let anyone near the machine.
2-17
PRECAUTIONS DURING OPERATION SAFETY
ENSURE GOOD VISIBILTY
When the machine is run or operated in a jobsite of low visibility, there is always a possibility that an operator gets
injured or causes a serious bodily injury, because they cannot see an obstacle around the machine or check the
conditions at the jobsite. Under such circumstances, therefore, strictly adhere to the following instructions.
q If the visibility at the jobsite is not good enough, post a signal person at an appropriate spot, and instruct the
operator to take heed of the signs and follow a signal from the signal person.
q Limit a signal person only to one.
q Instruct the operator to turn on the working lamp and headlamps of the machine in a dark spot. Install lighting
equipment additionally, if necessary, so that the jobsite can be brightly illuminated.
q When fog, snow, rain or dust hinders the visibility, stop the work.
CONFIRMATION OF MARK
On soft road shoulders or ground, set up signs to inform of the condition. If the operator does not know the condi-
tion of the jobsite, the machine may tip over or fall, resulting in injury to the operator. Make sure that all operation
personnel understand the meanings of all the signs.
PRECAUTION FOR WARNING TAG
When a warning sign of “DON'T OPERATE“ is hung to a con-

trol lever, it means the machine is now under repairs or mainte-
nance. Should you operate the machine, ignoring the warning
sign, someone else may get caught up in a rotating part or
pinched in a mobile portion of the machine, leading to a per-
sonal injury. Follow the warning sign and do not start up the
engine or touch a control lever.
CHECK BEFORE STARTING ENGINE,ADJUST
Before starting the engine, carry out the following checks to confirm that there is no problem with operating the
machine. If the checks are not carried out properly, there is danger that it may cause serious personal injury or
damage to the machine during operation.
q Wipe the dust and smudge off the windshield and window panes (when the machine is equipped with an oper-
ator's cab) so that the visibility is not lowered during the operation.
q Be sure to carry out “WALK-AROUND CHECK (3-53)“.
q Wipe the dust and smudge off the working light lens.
q Check that a mobile part like the brake pedal is free of accumulated dirt or a foreign material and works prop-
erly.
2-18
q Adjust the operator's seat so that it is easy to see to the front, and check that there is no damage or wear to
the seatbelt or seatbelt mounts.
q Check that the gauges work normally and that the control levers are in the neutral position.
q Before starting up the engine, check that the work equipment lock lever is in the LOCK position.
q Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat
q Check that there are no persons or obstacles above, below, or in the area around the machine.
PRECAUTIONS WHEN STARTING
q When starting the engine, always sit in the operator's seat. If you do not sit in the operator's seat, it will be
impossible to stop operations if a problem occurs. There is danger that this may lead to serious personal
injury.
q Before starting the engine, sound the horn to give a warning. If there is anyone in the area around the
machine, there is danger of serious injury when the machine moves.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a seri-
ous bodily injury or fire.
STARTING WITH BOOSTER CABLES
If the method of connecting the booster cables is mistaken, the

battery may explode and cause serious personal injury, so
always do as follows.
q Always wear safety goggles and rubber gloves when start-

ing the engine with booster cable.
q When connecting a normal machine to a problem machine

with booster cables, always use a normal machine with the
same battery voltage as the problem machine.
q When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the opera-
tor's seat and the other working with the battery).
q When starting from another machine, do not allow the two

machines to touch.
q When connecting the booster cables, turn the starting

switch OFF position for both the normal machine and prob-
lem machine. There is a hazard that the machine will move
when the power is connected.
q Be sure to connect the positive (+) cable first when install-

ing the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.
q When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch
the machine.
q For details of the starting procedure when using booster

cables, see “STARTING ENGINE WITH BOOSTER
CABLE (3-115)“ in the OPERATION section.
2-19
CHECK BEFORE STARTING OPERATION
Before starting the engine, carry out the “CHECK BEFORE STARTING (3-54)“ to confirm that there is no problem
with operating the machine. If this check is not carried out properly, there is danger that it may lead to damage dur-
ing operation or may lead to serious personal injury. When carrying out the checks, stop the machine in a wide
area where there are no obstacles, pay careful attention to the surrounding area, and operate slowly. Do not allow
any person to enter the area around the machine. If any problem is found, always repair the problem.
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE
q Operate the machine, being properly seated in the opera-

tor's seat without fail. Otherwise, you may not be able to
freely operate the machine in case of emergency, causing
a serious personal injury.
q Do not allow anyone else to ride the machine with you. As

there is no passenger seat provided, there is danger that
he or she may be seriously injured, when the machine tips
over during the operation.
q Always wear the seatbelt. There is danger that you may be

thrown out of the operator's seat and suffer serious injury
when the brakes are applied suddenly.
q If people are around the machine in the jobsite, there is

danger that they may get hit by or involved in the traveling
machine. Be sure to carry out the following instructions
before starting up the machine.
q Make sure that there is nobody around the machine

and that there is no obstacle in the traveling path.
q Blow a horn to warn people in the vicinity.
q Check that the backup alarm (a reverse travel warning

buzzer) keeps beeping normally, while the machine is
traveling in the reverse direction.
q If the visibility in the reverse direction is restricted, post

a signalman at an appropriate location.
2-20
PRECAUTIONS WHEN TRAVELING
q To avoid accidents caused by coming in contact with peo-

ple, structures, and other machines, always maintain the
proper distance when traveling.
q When traveling the machine on a flat land, hold the work

equipment at height (A) of 40 cm to 50 cm above the
ground. If that height is not maintained between the work
equipment and the ground, the work equipment may get
stuck in the ground and tip over.
q Do not attempt to climb over an obstacle. The machine

could roll over in the right or left direction. If the machine
climbs over an obstacle only with a track shoe on either
side, it can result in an overturn.
q When operating the machine near a bluff in the dozing

work, do not push the front blade up to the edge of the
bluff. If the blade is taken close to the edge, the bluff may
collapse under the machine and it rolls down.
q When traveling through a rough terrain, maintain a low

speed, and avoid a sudden sharp turn. Otherwise, the work
equipment may get caught up in the ground, causing the
machine to tip over.
PRECAUTIONS FOR ACCUMULATED SNOW, AND ICE
In a snowy or frozen jobsite, there is danger that the machine can skid, roll over or fall off during the operation or
traveling, causing a serious personal injury. Therefore, adhere to the following instructions without fail.
q Avoid abrupt operation of the machine during the work.
q Do not enter areas where the snow is deep. There is danger of driving off the road.
q Do not apply the brake suddenly on slopes. Reduce the speed and use the braking force of the engine
together with the foot brake (depress the foot brake repeatedly; do not keep it depressed) to stop the machine.
SHIPPING
When the machine is transported, there is danger of serious personal injury and damage during transportation.
Always do as follows.
q The machine weight, transportation height, and overall length differ according to the attachments installed.
Confirm the specifications of the machine before transporting it.
q Before deciding on a transportation route, check that the planned route can withstand a combined weight of a
trailer and the machine.
q When traveling on public roads, apply to the local authorities to obtain permission to transport the machine.
2-21
WHEN TOWING
For towing, see “METHOD OF TOWING MACHINE (3-112)“.
q Always confirm that the wire rope or drawbar used for tow-
ing has ample strength for the weight of the machine being
towed.
q Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope
may break during the towing operation.
q Always wear leather gloves when handling wire rope.
q Never tow a machine on a slope.
q During the towing operation, never stand between the tow-

ing machine and the machine being towed.
q Move the machine slowly and be sure not to apply any sud-
den load on the wire rope.
q If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic system,
the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the
brake circuit must be heightened to the specified level with a special device. Ask your Komatsu distributor.
2-22
SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE 2

UNAUTHORIZED MODIFICATION
If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety
and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as
machine strength and visibility. Before making any modifications, please consult your Komatsu distributor.
Komatsu cannot take any responsibility for accidents, failures, or damage caused by modifications not authorized
by Komatsu.
WARNING TAG
If others start the engine or operate the controls when it is

being serviced, there is danger that any person carrying out
repairs may suffer serious injury. ALWAYS attach the WARN-
ING TAG to the control lever to alert others the machine is in
repair.
KEEP WORK PLACE FOR MAINTENANCE CLEAN AND TIDY
q Always clean up spilled oil or grease, scattered tools and broken pieces.
q Do not use water or steam to clean the sensors, connectors, or the inside of the operator's compartment.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
USE CAUTION WHEN FUELING
q Never fill the fuel tank while smoking or when near an open flame.
q Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.
q Ground the fuel funnel or nozzle against the filler neck to prevent sparks and be sure to replace the fuel tank
cap.
PERSONAL MAINTENANCE
Do not allow anyone other than the maintenance personnel near the machine. If necessary, position a guard to
keep people out.
2-23
PRECAUTIONS FOR MAINTENANCE SAFETY
PROPER TOOLS
Always use the correct tools and handle them properly. Using
damaged or deformed tools or using tools for the wrong pur-
pose may cause injury.
SELECTION WORK PLACE FOR MAINTENANCE
When selecting the place to carry out inspection and maintenance, use flat firm ground that is safe for the opera-
tion, with no danger of landslide, falling rocks, or flooding.
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
q Always stop the machine before performing any inspection

and maintenance.
q Lower the work equipment to the ground and stop the

engine.
q Operate work equipment lock lever (1) and parking brake

lever (2) to the LOCK (L) position.
q Use chocks to immobilize the track shoes.
2-24
TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING
q Lower the work equipment to the ground and stop the

engine.
q Operate work equipment lock lever (1) and parking brake

lever (2) to the LOCK (L) position.
q Keep away from rotating parts.
q Do not touch the control levers except when it is necessary

to do so to carry out an inspection or maintenance work.
q Do not drop or insert any tools or parts.
WORK UNDER THE MACHINE
q Whenever it becomes necessary to go under the raised

machine or work equipment, be sure to support them with
blocks sturdy enough to withstand their weight. If it is
neglected to support them, the machine or work equipment
may fall off, causing a serious personal injury or death.
q Never use concrete blocks for supports. They can collapse

under even light loads.
q Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight of the com-
ponent. Never use jacks with cracked, bent or twisted parts. Never use frayed, twisted or pinched cables.
Never use bent or distorted hooks.
q When the track shoe is lifted using the work equipment, do not go under the machine. Otherwise, when it is
lowered, there is danger that a serious personal injury or death may be caused.
2-25
PRECAUTIONS WHEN USING HAMMER
In the work using a hammer, there is always a risk that a pin or

metal chips are sent flying, causing a serious personal injury. If
a flying metal chip gets in your eye, you may lose your eye-
sight. Adhere to the following instructions in this kind of work.
q Do not allow any person to come close to the worksite.
q Wear protective glasses, gloves and a hard hat.
PREVENTION BURNS FROM HOT WATER
Allow the radiator to cool before checking the level. If the radi-
ator cap is opened immediately after the engine is stopped, hot
water or steam may spurt out and cause burns.
To prevent burns, when inspecting or draining the coolant,

always:
q Check that the temperature has gone down to a point

where the radiator cap can be touched with your bare
hand.
q Loosen the cap slowly to release the pressure inside the

radiator, then take off the cap.
PREVENTION BURNS FROM HOT OIL
Immediately after the engine is stopped, the oil and parts are at
high temperature. If you touch the oil or parts immediately after
the engine is stopped, you will suffer burns.
q Check that the temperature has gone down to a point

where the cap can be touched with your bare hand, then
loosen the cap slowly and remove it.
q When removing the oil drain plug, release the internal pres-
sure, then remove the plug.
COMPRESSED AIR
q When compressed air is used for cleaning, dirt and dust will fly and may cause serious personal injury.
q When using compressed air to clean the element or radiator, wear safety glasses, anti-dust mask, gloves, and
other protective equipment.
HANDLING HIGH-PRESSURE HOSES, PIPING
q Do not bend hoses or hit them with hard objects.
q Do not use any bent or cracked piping, tubes or hoses as they may burst.
q Always repair loose fuel or oil hoses and consult with your Komatsu distributor if there are any damaged hoses
or piping.
2-26
PRECAUTIONS WITH HIGH-PRESSURE OIL
Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes and cause serious injury, blindness or
death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not
use your bare hand.
q Do not forget that the work equipment circuits are always under pressure.
q Do not carry out any inspection or replacement operation before the pressure has been completely removed.
q Check for cracks in the piping and hoses and for swelling in the hoses.
q Always wear safety glasses and leather gloves.
q If you are hit by a jet of high-pressure oil and suffer injury to

your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
Grease inside the track shoe tension adjuster is highly pressur-

ized. Do not make an error in the track shoe tension adjust-
ment steps, because a serious personal injury can be caused
by an error. Be sure to follow the steps correctly.
q When discharging grease to loosen the track shoe tension,

do not loosen plug (1) more than one turn. Otherwise, plug
(1) may suddenly spring out.
q Do not bring the face, hand, foot or other part of your body
near plug (1).
DO NOT DISASSEMBLE RECOIL SPRING
Do not disassemble the recoil spring as a cushion for the front idler. It is built in with a special jig, and if disassem-
bled carelessly, it will be ejected, causing a serious personal injury.
2-27
ACCUMULATOR
The accumulator contains highly pressurized nitrogen gas. A

failure to properly handle it can lead to an explosion, causing a
serious personal injury.
q Do not remove or disassemble unless necessary.
q Do not bring it near flame or dispose of it in fire.
q Do no make holes in it weld it, or use a cutting torch.
q Do not bear any shock by hammering, rolling or similar

activity.
q Ask your Komatsu distributor when sealing gas into the cyl-
inder or replacing gas from it.
MAINTENANCE OF AIR CONDITIONER
q Never touch the refrigerant.
q Never loosen any parts of the refrigerant circuit.
q Do not release any refrigerant to the atmosphere.
WASTE MATERIALS
q Always put oil drained from your machine in containers.

Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
q Obey appropriate laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.
2-28
SAFETY PRECAUTIONS FOR MACHINE
PRECAUTIONS FOR MACHINE 2

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)
When the machine rolls over, ROPS built in the operator's cab
absorbs the shock energy by supporting the machine's weight.
Thus an operator is protected from an accident. If this function
is hampered, a ROPS cab can no longer protect an operator
from injury. Therefore, adhere to the following instructions.
q Do not modify the ROPS by welding or drilling.
q If the ROPS has been deformed by a falling object or an

overturn, either repair or replace it with a new one. For the
repairs, call your Komatsu distributor.
2-29
PRECAUTIONS FOR MACHINE SAFETY
2-30
OPERATION
13
WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.
GENERAL VIEW OPERATION
GENERAL VIEW 3
GENERAL VIEW OF MACHINE 3

Machine equipped with ROPS cab
Machine equipped with ROPS canopy
(1) Blade (7) Sprocket

(2) Tilt cylinder (8) Track frame
(3) Lift cylinder (9) Frame
(4) Cab (10) Idler
(5) ROPS guard (11) ROPS canopy
(6) Track shoe
3-2
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES 3

Machine equipped with cab
(1) Parking brake lever (12) Fan rotation selector switch

(2) Work equipment lock lever (13) Starting switch
(3) Cigarette lighter (14) Information switch
(4) Fuel control dial (15) Buzzer cancel switch
(5) Steering, forward-reverse, gear shift lever (16) Brake pedal
(6) Auto shift down switch (17) Decelerator pedal
(7) Preset mode switch (18) Blade control lever
(8) Head lamp switch (19) Horn switch
(9) Air conditioner panel or heater panel (20) Ripper control lever (if equipped)
(10) Monitor panel (21) Wiper switch
(11) Rear lamp switch (22) Room lamp switch
3-3
GENERAL VIEW OPERATION
(1) Parking brake lever (10) Fan rotation selector switch

(2) Work equipment lock lever (11) Information switch
(3) Fuel control dial (12) Buzzer cancel switch
(4) Steering, forward-reverse, gear shift lever (13) Starting switch
(5) Auto shift down switch (14) Brake pedal
(6) Preset mode switch (15) Decelerator pedal
(7) Head lamp switch (16) Blade control lever
(8) Monitor panel (17) Horn switch
(9) Rear lamp switch (18) Ripper control lever (if equipped)
3-4
OPERATION GENERAL VIEW
MONITOR PANEL
(1) Display panel A (Speed range, Engine speed) (10) Warning lamp
(2) Power train oil temperature gauge (11) Engine coolant temperature caution lamp
(3) Engine coolant temperature gauge (12) Maintenance caution lamp
(4) Hydraulic oil temperature gauge (13) Engine pre-heating pilot lamp
(5) Fuel level gauge (14) Engine oil pressure caution lamp
(6) Hydraulic oil temperature caution lamp (15) Battery charge circuit caution lamp
(7) Power train oil temperature caution lamp (16) Display panel B (Multi-information)
(8) Fan operation confirmation lamp (17) Water Separator Lamp
(9) Filter/oil replacement interval lamp
3-5
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS 3
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
FRONT PANEL 3
A: Emergency caution items D: Lamp

B: Caution items E: Switch
C: Meter group
3-6
OPERATION EXPLANATION OF COMPONENTS
CHECK MONITOR SYSTEM 3
MONITOR SYSTEM
NOTICE
q Stop the machine on level ground and carry out the monitor check.
q Stop the engine, then turn the starting switch to the ON position and check that the lamps light up for
approx. 2 seconds. If they do not light up, please ask your Komatsu distributor to carry out inspec-
tion.
q The monitor check cannot be carried out until at least 5 seconds has passed after the engine was
stopped.
When carrying out the checks before starting, use the monitor system check.
1. Turn the starting switch to the ON position.
2. Check that the monitor liquid-crystal display and the lamps

all light up for 2 seconds, that the alarm buzzer sounds for
2 seconds, and that “KOMATSU SYSTEM CHECK“ is dis-
played for 3 seconds on display panel B (multi-information)
(1).
3.
q After 2 seconds, the current status of the machine is

displayed on liquid-crystal display (2).
q After 2 seconds, the lamp portion (3) goes out.
q After 3 seconds, the operating mode is displayed on

display panel B (multi-information) (1).
REMARK
The following cases do not indicate any problem.
If the preheating heater is actuated in cold weather, HEAT lamp
(4) does not go out until the preheating is completed.
If the oil or filter replacement interval has been reached, main-
tenance caution lamp (5) or filter oil replacement interval lamp
(6) light up or flash for 30 seconds, and the action code is dis-
played on display panel B (multi-information) (1).
3-7
EMERGENCY CAUTION ITEMS 3
CAUTION
If any of the caution lamps begins to flash, stop the engine or reduce the engine speed to low idle immedi-
ately and check the trouble spot for necessary actions.
These items must be monitored when the engine is running. If there is any problem, the caution lamp for the loca-
tion of the problem and warning lamp (A) flash, and the alarm buzzer sounds intermittently. Take the necessary
action immediately.
(1) Engine oil pressure caution lamp (4) Hydraulic oil temperature caution lamp
(2) Engine coolant temperature caution lamp (5) Water Separator Lamp
(3) Power train oil temperature caution lamp
ENGINE OIL PRESSURE CAUTION LAMP
This lamp (1) indicates low engine oil pressure.
If the monitor lamp flashes, stop the engine and check it imme-
diately.
REMARK
The alarm buzzer sounds, when the starting switch is turned to
ON immediately after the engine oil has been changed. It does
not indicate a problem.
3-8
ENGINE COOLANT TEMPERATURE CAUTION LAMP
This lamp (2) indicates a rise in the coolant temperature.
When the monitor lamp flashes, run the engine at low idle
speed until green range of the engine coolant temperature
gauge lights.
POWER TRAIN OIL TEMPERATURE CAUTION LAMP
This lamp (3) indicates a rise in the oil temperature of the

torque converter outlet.
When the monitor lamp flashes, run the engine at the low idling
speed until the green range of the power train oil temperature
gauge lights.
HYDRAULIC OIL TEMPERATURE CAUTION LAMP
Lamp (4) indicates a rise in the hydraulic oil temperature.
When the monitor lamp flashes, stop the machine and run the
engine at the low idling speed until oil temperature falls.
WATER SEPARATOR LAMP
This lamp (5) warns of a rise in the water level in the water sep-
arator. When it lights up, drain water from the water separator.
The water separator is located is in one piece with the fuel pre-
filter and located in the lower part.
For draining water from the water separator, see “CHECK,

DRAIN WATER SEPARATOR (3-56)“.
3-9
CAUTION ITEMS 3
CAUTION
If these caution lamps flash, check and repair the appropriate location as soon as possible.
These are items which need to be observed when the engine is running. If any problem occurs, the item needing
immediate repair is displayed. If there is any problem, the problem location on the caution lamp will flash.
(1) Battery charge circuit caution lamp (2) Maintenance caution lamp
BATTERY CHARGE CIRCUIT CAUTION LAMP
This lamp (1) indicates a problem in the charging system while

the engine is running.
If the monitor lamp flashes, check the V-belt tension. If any

problem is found, see “OTHER TROUBLE (3-117)“.
REMARK
This monitor lamp lights when the starting switch is turned to
ON immediately after the engine is started or immediately
before the engine is stopped. It does not indicate a problem.
3-10
MAINTENANCE CAUTION LAMP
This lamp (2) lights up for approx. 30 seconds after the starting
switch is turned to the ON position if the filter or oil replacement
interval has been reached.
After replacing the indicated filter or oil displayed on display

panel B (multi-information), reset the interval. For details, see
“METHOD OF USING OIL AND FILTER MAINTENANCE
MODE (3-23)“.
The lamp goes out.
REMARK
At the same time, the filter or oil replacement interval lamp also
lights up or flashes.
3-11
METER GROUP 3
(1) Engine coolant temperature gauge (5) Engine pre-heating pilot lamp
(2) Power train oil temperature gauge (6) Display panel A
(3) Hydraulic oil temperature gauge (Speed range display, Engine speed)
(4) Fuel leve gauge (7) Display panel B (multi-information)
ENGINE COOLANT TEMPERATURE GAUGE
NOTICE
If the coolant temperature gauge often enters red range (C), check the radiator for clogging.
Gauge (1) indicates temperature of the engine coolant.
If the temperature is normal during operation, green range (B)

will light.
If red range (C) lights during operation, move the fuel control
dial to lower engine speed to approx. 3/4 of the full speed, and
run until the coolant temperature enters green range (B).
If red range (C) lights up during operation, and the engine cool-
ant temperature caution lamp flashes and the alarm buzzer
sounds, stop the machine, run the engine at low idle, and wait
for the coolant temperature to return to green range (B).
(A): White range
(B): Green range
(C): Red range
3-12
POWER TRAIN OIL TEMPERATURE GAUGE
NOTICE
If the power train oil temperature gauge often enters the red range (C), we recommend you to lower the
travel speed one range (for example, F2 → F1) to reduce the load on the power train when operating.
Gauge (2) indicates the torque converter outlet oil temperature.

will light.
If red range (C) lights up during operation, move the fuel con-
trol dial to lower engine speed to approx. 3/4 of the full speed,
reduce the load and run until the oil temperature enters green
range (B).
If red range (C) lights up during operation, and the power train
oil temperature caution lamp flashes and the alarm buzzer
sounds, stop the machine, run the engine at low idle, and wait
for the oil temperature to go down to green range (B).
(A): White range
(B): Green range
(C): Red range
HYDRAULIC OIL TEMPERATURE GAUGE
Gauge (3) indicates the hydraulic oil temperature.

will light.
If the red range (C) lights up during operation, move the fuel
control lever to lower the engine speed to approx. 3/4 of the full
speed, reduce the load and run until the oil temperature enters
the green range (B).
(A): White range
(B): Green range
(C): Red range
FUEL LEVEL GAUGE
Gauge (4) fuel level in the fuel tank.
During normal operation, the green range (B) should be lit.
If red range (A) lights up during operation, add fuel immedi-

ately. If this is not done, the engine speed will become irrgular
or an error display will be shown on the monitor.
(A): Red range
(B): Green range
REMARK
The display is not proportional to the amount of fuel remaining.
If only the red range (A) lights up, there is less than 60 liters of
fuel remaining.
3-13
ENGINE PRE-HEATING PILOT LAMP
This lamp (5) indicates that the engine is being preheated with
an electric heater in cold weather.
When the engine starting switch is turned to the ON position,

the engine controller detects the engine coolant temperature
and automatically starts to preheat the engine at low tempera-
ture.
DISPLAY PANEL A (speed range display, engine speed)
Meter (6) displays the transmission speed range being used on

the machine and engine speed.
q The travel direction (A) and speed range (B) are displayed
in the center of the speed range display.
(A) F: FORWARD
R: REVERSE
N: Neutral
P: Parking brake lever at LOCK position
(B) 1: 1st
2: 2nd
3: 3rd
Example: F1 is displayed for FORWARD 1st
q Bar graph (C) around the outside of the display shows the engine speed.
If the bar graph reaches red range (D) during operation, take action to reduce the engine speed. Always keep
the bar graph in the green range.
DISPLAY PANEL B (multi-information)
The top and bottom lines in display panel B (multi-information) display information related to the condition of the
machine.
The content of the display is divided into “OPERATING MODE“ and “MAINTENANCE MODE“. Use the buzzer
cancel switch to switch between the operating mode and maintenance mode.
For details of switching the mode, see “BUZZER CANCEL SWITCH (3-21)“.
OPERATING MODE (default screen)
Use this mode when operating the machine.
REMARK
When the starting switch is turned from the OFF position to the ON position, display panel B (multi-information)
always displays the operating mode.
3-14
The following information is displayed by the operating mode.
Top line (A): Action code
If any problem occurs on the machine, an action code is dis-

played. If an action code appears, take the applicable action.
For details, see “OTHER TROUBLE (3-117).
This displays various types of filter or oil replacement intervals

have been reached.
Bottom line, left (B): Preset mode
When the preset mode switch is ON, the selected preset mode
is displayed.
For details of selecting the preset mode, see “GEARSHIFTING

OPERATION USING PRESET MODE FUNCTION (3-80)“.
Bottom line, right (C): Service meter or engine speed
Use the information switch to switch the display between the service meter and engine speed. For details of
switching the display, see “INFORMATION SWITCH (3-21)“.
Service meter
This displays the total number of hours that the machine has been operated. Use the display to determine the
intervals for periodic maintenance.
While the engine is running, the service meter advances, even if the machine is not being operated.
While the engine is running, the hourglass mark at the side of the meter flashes to show that the meter is advanc-
ing.
The meter advances 0.1h for every 6 minutes that the engine is running, regardless of the engine speed.
Maintenance mode
This displays various types of information related to mainte-

nance of the machine.
For details, see “METHOD OF USING MAINTENANCE MODE

(3-22)“.
3-15
LAMPS 3
(1) Warning lamp (3) Fan operation confirmation lamp

(2) Filter/oil replacement interval lamp
WARNING LAMP
(Red)
NOTICE
If alarm buzzer sounds, stop work immediately and perform inspection and maintenance of the appropri-
ate point.
This lamp (1) flashes when the caution lamp flashes and when
an action code is displayed on display panel B (multi-informa-
tion).
When the caution lamp (A) of an emergency warning item

flashes, or when the part of an action code is displayed, the
alarm buzzer sounds continuously at the same time.
3-16
FILTER/OIL REPLACEMENT INTERVAL LAMP
(Yellow)
If it is time to replace a filter or change the oil, this lamp (2)

lights up or flashes for approx. 30 seconds after the starting
switch is turned ON.
REMARK
This lamp (2) lights up if there is less than 30 hours remaining
until replacement, and flashes when the replacement interval
has passed.
At the same time, maintenance caution lamp (A) also lights up.
After replacing the indicated filter or oil displayed on display

panel B (multi-information), reset the time. For details, see
“METHOD OF USING OIL AND FILTER MAINTENANCE
MODE (3-23)“.
The lamp goes out or stops flashing.
FAN OPERATION CONFIRMATION LAMP
(Orange)
This lamp (3) lights up or flashes in the following operation, and

the fan begins to turn.
q When the engine starting switch is turned to the ON posi-

tion, and the engine is started up with this lamp (3) off, the
fan turns in the normal direction.
q After the engine starting switch is turned to the ON posi-

tion, and the fan rotation selector switch is turned to the
CLN position, this lamp (3) lights up. If the engine is started
up with lamp (3) on, the fan turns in the reverse direction.
q If the fan rotation selector switch is turned to CLN position

while the engine is running, this lamp (3) flashes for three
seconds, indicating that the fan rotation direction has not
changed.
3-17
SWITCHES 3
(1) Starting switch (5) Rear lamp switch

(2) Auto shift down switch (6) Fan rotation selector switch
(3) Preset mode switch (7) Information switch
(4) Head lamp switch (8) Buzzer cancel switch
3-18
STARTING SWITCH
This switch (1) is used to start or stop the engine.
(A): OFF position
At this position, the starting switch key can be inserted and

removed. When the switch is turned to this position, all the
electric circuits are turned off and the engine stops.
(B): ON position
In this position, electric current flows in the charging and lamp

circuits.
Keep the starting switch key at the ON position while the

engine is running.
(C): START position
This is the position to start the engine. Hold the key at this position while cranking the engine. Release the key
immediately after the engine has been started. The key will return to ON position (B) when released
AUTO SHIFT DOWN SWITCH
This switch (2) is used to actuate the auto shift down function
and shift the transmission automatically to a low speed range.
Q (OFF) position: Stopped
l (ON) position: Actuated
For details, see “AUTO DOWN SHIFT OPERATION (3-82)“.
PRESET MODE SWITCH
This switch (3) is used to actuate the preset mode function.
Q (OFF) position: Stopped
For details, see “GEARSHIFTING OPERATION USING PRE-

SET MODE FUNCTION (3-80)“.
3-19
HEAD LAMP SWITCH
This switch (4) lights up when the front lamp, and panel lamp
light up.
Q (OFF) position: Lights out
l (ON) position: Lights on
REAR LAMP SWITCH
This switch (5) lights up the rear lamps.
Q (OFF) position: Lights out
l (ON) position: Lights on
FAN ROTATION SELECTOR SWITCH
This switch (6) is used to switch the direction of rotation of the

cooling fan.
When it is released from the CLE position, it will automatically

return to the Q position.
Qposition : Normal rotation
Use this switch normally with the fan operation

confirmation lamp in the OFF condition.
Cooling air is blown out to the front from the radiator mask.
The fan turns in RPM commensurate with the cooling water

temperature, thus assuring effective cooling of the engine.
CLN position: Cleaning
Use this switch with the fan operation confirmation lamp in the
ON condition.
The fan turns in the reverse direction and at a high speed with-
out any relation to the cooling water temperature.
Use this mode to clean the radiator fins.
For the “ON“ or “OFF“ condition of the fan operation confirmation lamp, see “FAN OPERATION CONFIRMATION
LAMP (3-17)“.
3-20
REMARK
The fan rotation direction cannot be changed, even if it is tried
when the engine is running.
The fan operation confirmation lamp begins to flash to tell you
that the fan rotation direction cannot be changed.
When the fan operation check lamp lights up and the fan is
turning in the reverse direction, the machine does not start
even if the steering - forward / reverse shifting- gearshift lever
is operated to the FORWARD or REVERSE position. This is to
protect the radiator. To start the machine, turn the engine start-
ing switch key to the OFF position once and then turn to the
ON position once again, after making sure that the fan opera-
tion check lamp has gone off.
When the fan is turning to clean the radiator fins, and the
engine starting switch is turned to the OFF position, power is
not switched off immediately in order to protect the hydraulic
circuit.
INFORMATION SWITCH
This switch (7) is used to operate display panel B (multi-infor-

mation).
When the switch is released, it returns automatically to the cen-

ter position.
q When display panel B (multi-information) is in the

operation mode
turn the switch to < or > to switch the display to service
meter or engine speed.
q When display panel B (multi-information) is in the

maintenance mode
It is used to move between sub modes, between items, to
move the cursor, or to change values.
For details, see “METHOD OF USING MAINTENANCE

MODE (3-22)“.
BUZZER CANCEL SWITCH
This switch (8) is used to operate control panel B (multi-infor-

mation) or to stop the alarm buzzer.
When the switch is released, it returns automatically to the cen-

ter position.
q When display panel B (multi-information) is in operation

mode
q When the alarm buzzer is sounding, turn this switch to

the left or right to stop the buzzer.
q If the switch is held at the U position for at least 2.5

seconds, the display switches to the maintenance
mode.
3-21
q When display panel B (multi-information) is in the maintenance mode
t position: Cancel or reset to operation mode
U position: Confirms selection or selected item
For details, see “METHOD OF USING MAINTENANCE MODE (3-22)“.
METHOD OF USING MAINTENANCE MODE 3

To switch from the operation mode to the maintenance mode,
turn the buzzer cancel switch to the U position and hold it
there for at least 2.5 seconds. The screen will switch to the
maintenance mode.
On the first screen, the oil and filter maintenance mode is dis-
played.
EXPLANATION OF MODES AND OPERATION
The maintenance mode has the following 4 sub modes.
Sub mode Function Reference items

Oil or filter replacement time is dis- METHOD OF USING OIL AND FILTER
Oil/filter maintenance mode
played MAINTENANCE MODE (3-23)
The engine RPM and battery volt- METHOD OF USING PM CLINIC AUXIL-
PM clinic auxiliary mode
age are shown. IARY MODE (3-25)
Fault codes for electronic control METHOD OF USING FAULT CODE DIS-
Fault code display mode
related parts are displayed PLAY MODE (3-26)
METHOD OF USING USER ADJUST
Adjustment mode Adjusts monitor brightness, etc.
MODE (3-26)
Use information switch (1) and buzzer cancel switch (2) to

operate each mode.
3-22
METHOD OF SELECTING EACH MODE
Operating mode
(Hold for 2.5 sec)
Oil/filter maintenance mode

Detailed item display
PM clinic auxiliary mode

Fault code display mode

Adjustment mode
(To oil/filter maintenance mode)
METHOD OF USING OIL AND FILTER MAINTENANCE MODE
NOTICE
This function is only a guideline. If dirty oil or filters are found during daily maintenance, replace them
immediately.
If the controllers or monitor panel are replaced, the timer for this function will not work properly. Contact
your Komatsu distributor for replacement.
3-23
In the oil and filter maintenance mode, the replacement inter-

vals for oil and filters are displayed on display panel B (multi-
information).
(1) The item is displayed.
(2) The time remaining until replacement is displayed.
(3) The quantity of replacements until now is displayed.
The display items can be displayed in order by operating the

information switch to the left or right (<, >).
Replacement Interval (h)

Code Display Maintenance Work Item 1st Replacement (may not be 2nd Replacement and there-
changed) after (may be changed)
01 ENG OIL Engine oil 500h (**) 500h (**)
02 ENG FILT Engine oil filter 500h (**) 500h (**)
03 FUEL FILT Fuel main filter 1000h 1000h
04 HYD FILT Hydraulic oil filter 2000h 2000h
06 CORR RES Corrosion resistor 1000h 1000h
07 DAMP OIL Damper oil 2000h 2000h
08 FNL OIL Final drive oil 1000h 1000h
10 HYD OIL Hydraulic oil 2000h 2000h
12 HSS FILT HSS charge filter (*) - -
19 POWL OIL Power train oil 1000h 1000h
20 POWL FILT Power train oil filter 500h 500h
41 F. PRE-FLT Fuel pre-filter 500h 500h
q The 1st replacement interval may not be changed. If it needs to be changed for some particular reason, treat
the 1st maintenance work as has been finished in the maintenance mode, and change the 2nd or subsequent
replacement interval.
q The item with an asterisk (*) in the table is shown on the display but not in use in this machine.
q (**) For details about engine oil interval, refer to section, RECOMMENDED FUEL, COOLANT, AND LUBRI-
CANT (4-12)
When the oil or filter has been replaced, select the applicable
item, then operate the buzzer cancel switch to U.
The screen will ask if you want to display the replacement his-
tory.
Operate the information switch to select YES, then operate the

buzzer cancel switch to U. The replacement quantity will
increase by 1, the replacement interval will be reset, and the
oil, filter change interval lamp will go out.
When this is done, if the maintenance caution lamp does not

go out, there is another item close to the replacement time, so
check that item.
3-24
REMARK
To return to the maintenance mode, operate the buzzer cancel
switch to t.
METHOD OF USING PM CLINIC AUXILIARY MODE
CAUTION
When moving the work equipment or setting the transmission to the travel position for carrying out mea-
surements, check carefully that the situation is safe.
In the PM Clinic auxiliary mode, the engine RPM and battery voltage are shown in display B (multi-information).
Display panel B (Malti-information) displays the item on the top

line (1) and the measured value on the bottom line (2).
The display items consist of the seven items in the table below.
The items can be selected by operating the information switch (<, >).
Display Item Measured value

01-ENG SPEED Engine rotation speed Rotation (rpm)
Engine cooling water tem-
02-COOLANT TEMP. Temperature (°C)
perature
05-BOOST PRESS. Boost pressure Pressure (kPa)
06-BOOST TEMP. Boost temperature Temperature (°C)
07-T/C TEMP. Power train oil temperature Temperature (°C)
Work equipment oil temper-
08-HYD TEMP. Temperature (°C)
ature
13-BATTERY VOLT. Battery voltage Voltage (mV)
REMARK
Items such as the engine speed fluctuate and are difficult to see during the measurement. In such cases, operate
the buzzer cancel switch to U. This makes it possible to hold the display of the value.
To cancel this mode, operate the buzzer cancel switch again to U.
To return to the maintenance mode, operate the buzzer cancel switch to t.
3-25
METHOD OF USING FAULT CODE DISPLAY MODE
NOTICE
The fault items observed by this function are connected with the electronic control, so even if a fault code
is not displayed, there is probably some problem with the machine. If the operator feels any problem with
the machine, the machine should be stopped immediately and checked.
When any disconnection or short circuit in any sensor is detected, the location and fault code are displayed by a 6-
digit code on display panel B (multi-information). When contacting your Komatsu distributor, inform your distributor
of the code at the same time.
If the failure observation function has not determined the condi-

tion of the machine, the display is as shown in the diagram on
the right.
With this function, existing failures can be displayed up to a

maximum of 20 items.
If multiple failures are occurring, the display automatically

changes every 2 seconds, so check the code (1).
The display is shown repeatedly.
REMARK
METHOD OF USING USER ADJUST MODE
The adjust mode has functions of changing the intensity of the panel backlight and the contrast of LCD panel. They
are shown in display B.
1. Adjusting backlighting of liquid crystal display
2. The diagram on the right is the mode for adjusting the

brightness of the backlighting of the liquid crystal panel.
This display will be switched to the screen brightness

adjustment display, if the alarm buzzer cancellation switch
is turned to the U position.
3-26
3. The brightness can be adjusted by operating the informa-

tion switch.
The higher the number, the brighter the screen becomes;

the lower the number, the darker the screen becomes.
> position: Number increases
< position: Number decreases
4. The brightness of the backlight for the LCD gauges may be

held constant by turning the alarm buzzer cancellation
switch to the U position.
REMARK
The brightness of the backlighting of the monitor panel differs according to whether the front lamp is lit or not.
Entering this mode when the front lamps are lit makes it possible to adjust the brightness when the front lamps are
lit. In the same way, entering this mode when the front lamps are not lit makes it possible to adjust the brightness
when the front lamps are not lit.
5. Adjusting backlighting of display panel B (multi-information)
6. The diagram on the right is the mode for adjusting the

brightness of the backlighting of the display panel B (multi-
information).
On the screen, operate the buzzer cancel switch to U to

switch to the screen for adjusting the brightness.
7. The brightness can be adjusted by operating the informa-

tion switch.
The higher the number, the brighter the screen becomes;

the lower the number, the darker the screen becomes.
3-27
8. When the buzzer cancel switch is operated to U, the

brightness of the display panel B (multi-information) back-
lighting is set.
REMARK
The brightness of the backlighting of the monitor panel differs according to whether the front lamp is lit or not.
Entering this mode when the front lamps are lit makes it possible to adjust the brightness when the front lamps are
lit. In the same way, entering this mode when the front lamps are not lit makes it possible to adjust the brightness
when the front lamps are not lit.
9. Adjusting contrast of liquid crystal display panel B (multi-information)
10. The diagram on the right is the mode for adjusting the con-
trast of the liquid crystal display panel B (multi-information).
On this screen, operate the buzzer cancel switch to U to

switch to the screen to adjust the contrast.
11. The contrast can be adjusted by operating the information

switch.
The higher the number, the deeper the screen becomes;

the lower the number, the lighter the screen becomes.
12. When the buzzer cancel switch is operated to U, the con-

trast of the liquid crystal display panel B (multi-information)
is set.
REMARK
3-28
SWITCHES 3
(1) Fuel control dial (5) Cigarette lighter

(2) Horn switch (6) Accessory socket
(3) Room lamp switch (7) Rear glass heating switch
(4) Wiper switch (EU specification)
3-29
FUEL CONTROL DIAL
Dial (1) is used to control the engine speed and output.
(a) Low idling position: Turn fully to the left
(b) High idling position: Turn fully to the right
HORN SWITCH
The horn sounds when the button (2) at the rear of the blade
control lever at the right side of the operator's seat is pressed.
ROOM LAMP SWITCH
This (3) illuminates the room lamp.
(A) ON position: Lamps light up
(B) OFF position: Lamps are out
WIPER SWITCH
This (4) activates the wipers.
The wiper switches are as follows:
(A): Left door (LH)
(B): Front window (FF)
(C): Right door (RH)
(D): Rear window (RR)
(E): Wiper intermittent operation switch (INT)
This is also used as the window washer switch.
The switch is operated as follows:
3-30
q Wiper only
(J) ON position: Wiper is operated
(K) OFF position: Wiper stops
q Wiper and window washer
If this is kept pressed to the ON position (J) while the wiper

is working, water will be sprayed out.
q Only wind washer
If this is kept to the OFF position (K), water will be sprayed

out.
q Wiper intermittent operation switch
When this switch is turned to the ON position (J) to start

the wiper moving, the wiper works once in every four sec-
onds.
REMARK
When the wiper intermittent operation switch is ON position (J),
if the wiper switch for each window is turned ON position (J),
the wiper will move intermittently.
3-31
CIGARETTE LIGHTER
This (5) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after a few seconds, so take it out to light your cig-
arette.
If the cigarette lighter is removed, the socket can be used as a

power source.
NOTICE
This cigarette lighter is 24V. Do not use it as the power
source for 12V equipment. If it is used so, the equipment
may fail.
The capacity of the cigarette lighter is 120W (24V x 5A).
ACCESSORY SOCKET
This (6) is used as the power source for a wireless or other 12V
equipment.
Accessory socket capacity: 60W (12V x 5A)
REAR GLASS HEATING SWITCH
This switch (7) is used to actuate the rear glass heater wire
defroster in order to remove the mist from the glass.
ON position: Actuated
ON
At the same time, indicator (A) lights up.
OFF position: Stopped

OFF
3-32
CONTROL LEVERS AND PEDALS 3
(1) Work equipment lock lever (4) Brake pedal

(2) Parking brake lever (5) Decelerator pedal
(3) Steering, forward-reverse, gear shift lever (6) Blade control lever
WORK EQUIPMENT LOCK LEVER
WARNING
q When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK
position. If the work equipment lock lever is not at the LOCK position and the control levers are
touched by mistake, it may lead to serious personal injury.
q If the work equipment lock lever is not set securely to the LOCK position, the work equipment may
move and cause serious injury. Check that it is in the position shown in the diagram.
q When parking the machine or when carrying out maintenance, always lower the work equipment to the
ground, then set the work equipment lock lever to the LOCK position.
This lever (1) is a lock device for the work equipment control
lever.
(L) LOCK position: Work equipment does not move even when
work equipment control lever is operated
(F) FREE position: Work equipment moves according to opera-

tion of work equipment control lever
REMARK
When starting the engine, to ensure safety, always set the work
equipment lock lever to the LOCK position.
3-33
PARKING BRAKE LEVER
WARNING
q When parking the machine, always set the parking brake lever in the LOCK position.
q If the parking brake lever is operated, the brake is applied, even when the machine is traveling.
The machine will suddenly stop, so this is dangerous. For this reason, do not operate the parking
brake lever when the machine is moving, except in emergencies.
This lever (2) is the control lever for the parking brake.
(L) LOCK position: Parking brake is applied
(F) FREE position: Parking brake is released
REMARK
Before moving the parking brake lever to the LOCK position,
return the steering, forward-reverse, gear shift lever to the
NEUTRAL position.
When starting the engine, if the parking brake lever is not in the
LOCK position, the limit switch is actuated and it is impossible
to start the engine.
STEERING, FORWARD-REVERSE, GEAR SHIFT LEVER
This control lever (3) serves to change forward or reverse direction of machine travel, steer the machine to the
right or left, change the traveling speed and make a counter-rotation.
q Forward-reverse shifting
Position (A): FORWARD
Position (B): REVERSE
Position (N): NEUTRAL
Operate the lever to the front to travel FORWARD.
Operate the lever to the rear to travel in REVERSE.
q Steering
Position (L): Left turn
Position (R): Right turn
If the lever is set in the forward or reverse travel position and moved to the left or right, the machine will turn in the
direction that the lever is moved. The turning radius changes according to the amount that the lever is moved. If
the lever is moved fully to the left or right, the turning radius will become smaller.
REMARK
When moving the joystick lever, and the lever is released, it will return to (A) or (B) and the machine will travel in a
straight line.
3-34
q Gear shifting
When UP switch (U) or DOWN switch (D) is pushed, the trans-

mission speed will change.
UP switch (U): Each time the switch is pressed, the transmis-

sion will up shift one speed.
DOWN switch (D): Each time the switch is pressed, the trans-
mission will down shift one speed.
There are 3 forward and 3 reverse speed ranges.
For details of the maximum speed in each speed range, see

“SPECIFICATIONS (5-2)“.
REMARK
The speed range being used is displayed on panel A on the monitor panel according to the gearshift operation.
<Example>
Neutral: N is displayed on the display panel.
FORWARD 2nd: F2 is displayed on the display panel.
REVERSE 3rd: R3 is displayed on the display panel.
When the parking brake lever is locked, P is displayed.
For details of the method of shifting gears according to the shift mode, see the “SHIFTING GEARS (3-79)“. Shift
mode selection means that the selected speed range is displayed at the NEUTRAL position (N) before starting.
q Operating counter-rotation turn
WARNING
When operating the counter-rotation turn, if the load on the left and right is not balanced, the machine may
make a pivot turn, so check the ground conditions and be careful not to hit any obstacles when carrying
out the operation.
With the lever at the NEUTRAL position (N), move the lever
partially in the direction of turn. The left and right tracks will
rotate in opposite directions, and the machine will make a slow
counterrotation turn. If the lever is operated further, the speed
of the counterrotation turn will increase.
(R): Right counterrotation turn
(L): Left counterrotation turn
3-35
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
Depress the pedal (4) to apply the right and left brakes.
DECELERATOR PEDAL
WARNING
q Do not place your foot on this pedal unnecessarily.
q When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly
reduced, so there is danger that the travel speed will also increase suddenly. To prevent this, depress
the decelerator pedal to reduce the travel speed.
This pedal (5) is used when reducing the engine speed or stop-
ping the machine.
When switching between forward and reverse, or when stop-

ping the machine, use this pedal to reduce speed.
3-36
BLADE CONTROL LEVER
POWER TILTDOZER
This lever (6) is used to lift or tilt the blade.
q Lifting control
(A) RAISE: Blade goes up
(B) HOLD: Blade is stopped and held in this position.
(C) LOWER: Blade goes down
(D) FLOAT: Blade will move freely according to external force.
REMARK
If the lever is in the FLOAT position, even when it is released, it
does not return to the HOLD position, so return it by hand.
If the engine is stopped when the control lever is in the FLOAT
position, the lever is returned automatically to the HOLD posi-
tion.
In low temperatures, it may take a short time for the blade con-
trol lever to be held in the FLOAT position, so hold the lever in
position for at least 1 second.
q Tilting control
(E) LEFT TILT
(F) RIGHT TILT
3-37
POWERTILT POWER PITCHDOZER
This lever (6) is used to lift or tilt and pitch the blade.
q Lifting control
REMARK
tion.
q Tilting control
(E) LEFT TILT
(F) RIGHT TILT
3-38
q Pitch control
After moving the lever to the neutral position without fail, tilt the
blade while pressing any of the switches (M) in the center of
the knob. Then the angle of the blade edge changes.
(B) Hold: The blade stops and holds a stationary posture.
(G) Rear pitch: Blade edge angle small
(H) Front pitch: Blade edge angle large
q Precautions when using pitch control
When using the pitch operation, the tilt operation changes as

follows.
(G) Rear pitch

(H) Front pitch
(J) Pitch gauge
(K) Standard pitch
D65EX D65PX D65WX

Pitch condition Tilt operation
Amount of tilt
Max. forward Only left tilt
Max. 870 mm Max. 890 mm Max. 820 mm
pitch operation is possible
Compared with standard:
Forward pitch (H) LEFT tilt is LARGER
RIGHT tilt is SMALLER
Both left and right tilt
Standard pitch 460 mm 450 mm 410 mm
operations are possi-
(K) (both left and right) (both left and right) (both left and right)
ble
Compared with standard:
Rear pitch (G) LEFT tilt is SMALLER
RIGHT tilt is LARGER
Only right tilt
Max. rear pitch Max. 870 mm Max. 890 mm Max. 820 mm
operation is possible
3-39
ANGLE DOZER
This lever (6) is used to lift or tilt the blade.
q Lifting control
REMARK
tion.
3-40
CIRCUIT BREAKER 3
NOTICE
q When resetting the circuit breaker, always turn off the power first (turn the starting switch OFF).
q If the reset button for the circuit breaker comes out immediately when it is pushed in, it is necessary to
carry out an inspection of the electrical circuit.
If the starting switch does not work when it is turned to the ON position, the circuit has probably been cut off by the
circuit breaker.
Inspect the circuit breaker.
REMARK
The circuit breaker is a device installed in electric circuits where a large current flows. It is installed to protect the
electric circuit. It protects the electric components and wiring from damage caused by an abnormal current in the
same way as a normal fuse. After repairing and restoring the location of the abnormality, there is no need to
replace the breaker. It can be used again.
1. Open the cover at the bottom of the front panel. Circuit

breakers (1) and (2) can be seen.
(Circuit breaker (2) is installed only on machines equipped

with an air conditioner.)
2. When the circuit breaker has cut off the circuit, reset button
(3) springs out.
Push reset button (3) in.
Fuse
No Circuit
capacity
(1) 20A Starting switch
(2) 20A Air conditioner
FUSE 3
NOTICE
Before replacing a fuse, be sure to turn starting switch to the OFF position.
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the
fuse.
Replace the fuse with another of the same capacity.
3-41
q Chassis
Fuse boxes (A) and (B) are installed under the battery cover.
q Cab (machines equipped with cab)
Fuse box (C) is installed in the overhead panel.
FUSE CAPACITY AND CIRCUIT NAME
Fuse box (A)
Fuse
NO. Circuit
capacity
(1) 20A Spare power source
Horn, Ribbon heater,
(2) 20A
Air suspension seat
(3) 20A Front lamp, Rear lamp
Transmission,
(4) 20A
Steering controller
(5) 5A Engine controller
Fuse box (B)
Fuse
NO. Circuit
capacity
(1) 5A Backup alarm
(2) 15A Continuous power source
(3) 30A Truck power source
(4) 30A Engine power source
(5) 30A Air conditioner
3-42
Fuse box (C)
Fuse
NO. Circuit
capacity
(1) 10A Radio memory
(2) 20A Radio,lamp,cigarette lighter
(3) 20A Heated glass (EU specification)
(4) 10A Rear wiper
(5) 10A Front wiper
(6) 10A Left and right door wiper
FUSIBLE LINK 3
If any of the electrical equipment in the operator's cab does not work, a fusible link built in the wiring harness is
suspected of disconnection. In that case, check the link and replace it with a new one, if necessary.
REMARK
A fusible link refers to the large-sized fuse wiring installed in the high current flow portion of the circuit to protect
electrical components and wiring from burning, similar to an ordinary fuse.
When opening the battery cover on the left side of the truck,
you can see fusible link (1) and (2).
Capacity of fusible link (1): 65A
Capacity of fusible link (2): 120A
ELECTRIC POWER TAKE-OUT ADAPTER 3
MACHINE EQUIPPED WITH CAB 3
NOTICE
The power for the cigarette lighter is 24V. Do not use it as
the power source for 12V equipment.
The cigarette lighter socket (1) can be used as a power source

for 24V equipment and the accessory socket (2) can be used
for 12V equipment.
Capacity of cigarette lighter: 120W (24V x 5A)
Capacity of accessory socket: 60W (12V x 5A)
3-43
MACHINE EQUIPPED WITH ROPS CANOPY 3

NOTICE
q Do not use as a power supply for 12V equipment.
This will cause failure of the equipment.
q When using as a power supply pickup, do not install equipment which exceeds 120W (24V x 5A).
1. Open the battery cover on the left side of the machine

body.
2. There is the connector for the spare power take-off.
(Connector CN800 (3) can be used.)
DOOR - OPEN LOCK 3

(Machine equipped with cab)
Use this when your want to keep the door held open.
1. Push the door against the door catch (1). The door will be
held by the door catch.
2. To release the door, move lever (2) inside the cab to the
front of the cab. This will release the catch.
NOTICE
q When keeping the door open, fix it securely to the
catch.
q Always close the door when traveling or carrying out

operations. Leaving the door open will cause the door
to break.
q Keep the door locked open securely. The door may

swing closed because of the vibration.
3-44
SASH GLASS INTERMEDIATE LOCK 3

When working with the cab sash glass open, use this lock to
prevent the glass from chattering.
q When the lever is in the FREE position (F), the glass can
be opened or closed.
q When the lever is in the LOCK position (L), the glass is

held in position.
DOOR POCKET 3
This is inside the left and right doors. Use it for storing the
Operation and Maintenance Manual or other things.
Do not put heavy tools or other heavy objects in it.
If the pocket is dirty, turn 4 clips (1), then remove the pocket
and rinse it.
3-45
OPENING AND CLOSING ENGINE SIDE COVER 3

When opening
Pull door release lever (1) to release the lock, then pull the
cover up.
When closing
NOTICE
When closing the cover, always release the gas damper lock first.
If the gas damper lock is not released and any attempt is made to close the cover, the gas damper may
break.
Push the orange button in the center of the gas damper (1) to
release the lock, then push the cover down.
ASHTRAY 3
This is on the left side of the operator's seat.
Always make sure that you extinguish the cigarette before clos-
ing the lid.
3-46
CUP HOLDER 3
(If equipped)
This is the place to put cans or cups.
If drinks are put in places other than the cup holder, the can or
cup will fall over and make the surrounding area or equipment
dirty.
Please make full use of the cup holder.
TOOL BOX 3
The tool box is inside the battery check cover at the rear left.
Keep the tools in this box.
SHOVEL HOLDER 3
(If equipped)
This can be used for storing a shovel with a rounded blade.
q Method of installing
1. Position the shovel with stopper (1) and holder (2).
2. Tighten the adjustment nut (3) so the shovel does not

move.
3-47
AIR CONDITIONER, HANDLING 3

(Machine equipped with cab) (if equipped)
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos-
sible to provide a pleasant working environment even on dusty jobsites.
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 3
(1) Fan switch (5) Defroster

(2) Air conditioner switch (6) Air flow to foot
(3) Fresh/recirc selector switch
FAN SWITCH
This switch (1) can be used to adjust the airflow in four stages.
It also acts as the main switch for the air conditioner. When the
OFF switch is pressed, the fan stops.
When the switch is pressed, the indicator lamp above the

switch lights up to display the airflow.
3-48
AIR CONDITIONER SWITCH
This switch (2) is used to start or stop the cooling or dehumidi-

fying function.
When the fan switch is turned ON and the air conditioner

switch is pressed, the indicator lamp above the switch lights up.
When the switch is pressed again, the switch is turned OFF
and the indicator lamp goes out.
FRESH/RECIRC SELECTOR SWITCH
This switch (3) is used to select between recirculation of the air

inside the cab or intake of fresh air from outside.
When the switch is pressed, indicator lamp (A) at the top of the
switch lights up.
Recirculation of air inside cab
Press this switch (B) to use only the air inside the cab. Use this position to carry out rapid heating or cooling of the
cab or when the outside air is dirty.
Intake of fresh air from outside
Press this switch (C) to carry out heating or cooling with fresh air taken in from the outside. Use this position when
fresh air is taken in from outside the cab, or when removing the mist from the cab windows.
REMARK
When fresh air is taken into the cab, air pressure in the cab increases, which prevents the dust from entering.
When neither heating nor cooling is needed, bring in clean fresh air, with your preferred air flow, to prevent dust
from entering the cab.
TEMPERATURE CONTROL SWITCH
The temperature can be adjusted with this switch (4) gradually

from low temperature to high temperature.
The temperature level indicator lamps (A) light up to display the

temperature of the air coming from the vents.
The more blue lamps on, the lower the temperature is.
The color of the indicator lamp (A) changes while the switch is
being pressed.
When the temperature reaches the desired level, release the

switch to set the temperature.
3-49
The settings for each mode are retained in memory even when the starting switch is turned OFF.
However, in the following cases, the settings must be reset.
q When the machine has been out of use for more than 7 days
q When the battery voltage is extremely low
q When there has been abnormal interference from outside
q When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)
If the air conditioner is used in the FRESH position, the inside of the cab will be pressurized and this will prevent
the entry of dust.
The higher the position of the fan switch, the more effective the pressurizing becomes.
METHOD OF OPERATION 3
Switch Air conditioner Temperature FRESH/RECIRC

Fan switch
Condition of use switch control switch selector switch
Rapid HI ON All blue RECIRC
Cooling More than half
Normal HI - LO ON FRESH
are blue
More than half
Dehumidifying, heating HI - LO ON FRESH
are red
Rapid HI OFF All red RECIRC
Heating More than half
Normal HI - LO OFF FRESH
are red
More than half
Defroster HI ON FRESH
are red
Vetilation or pressurizing HI - LO OFF All blue FRESH
When defrosting, set the temperature control switch so that all

lamps are red. This will improve defrosting and demisting.
WHEN NOT USING THE AIR CONDITIONER REGULARLY
Run the air conditioner in cooling or dehumidification + heating mode for several minutes from time to time to pre-
vent the loss of the oil film in various parts of the compressor.
REMARK
If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recirculated air to
warm up the inside of the cab, then turn the air conditioner switch on. The air conditioner will be run.
3-50
COOL BOX
When the cooling is being used, this can be used for keeping
drinks and other things cool.
When the heating is being used, it can be used to keep things

warm.
Do not use the cool box for things which smell or leak water or
break easily.
Do not use it as a holder for tools or other small objects.
PRECAUTIONS WHEN USING 3
PRECAUTIONS WHEN USING THE COOLING 3

q If you smoke when using the air conditioner in the RECIRC mode, your eyes may start to itch or burn. Ventilate
the cab ever so often to remove the smoke.
q When using the air conditioner for a long period of time, carry out ventilation process at least once every hour.
When using the air conditioner, it is recommended for health reasons, that it should only feel slightly cooler (5 or
6°C lower than the outside temperature) when you enter the cab.
Therefore, adjust the temperature to a suitable level.
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE 3
q If the vents (left and right) in the middle of the dashboard are turned so that cold air blows directly on the cab
door glass, moisture may condense on the outside of the cab door glass and reduce the visibility. (This occurs
particularly in high temperatures.)
If this happens, close the louvers of the vent and change the direction to prevent the cold air from blowing
directly on the surface of the glass.
INSPECTION DURING OFF-SEASON 3

Even during the off-season, run the compressor at low speed for several minutes once a week to prevent the loss
of the oil film on the lubricated parts of the compressor. (Run the engine at low speed and set the temperature con-
trol lever to the central position.)
REMARK
When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause failure of the
compressor. Note that the system is set so that the compressor will not run when the cooler switch is turned on, if
the ambient temperature is less than 2 to 6.5°C.
PROCEDURE FOR REPLACING RECEIVER 3

Replace the receiver once every 2 years.
After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining
inside the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver.
3-51
REMARK
The replacement interval may become shorter depending on the conditions during use.
If the receiver is used when the moisture absorption limit of the desiccant has been exceeded, the refrigerant cir-
cuit may become blocked and cause the compressor to break down.
PRECAUTIONS WHEN REPLACING RECEIVER
q If the receiver is left for more than 15 minutes with the blind cover removed, the moisture in the air will be
absorbed, and this will reduce the life of the desiccant. If you remove the blind cover, connect the piping
quickly, evacuate the system and fill with refrigerant.
q When removing the refrigerant from the refrigerant circuit, release it gradually from the low pressure side to
prevent oil from flowing out.
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL 3

If the compressor belt is loose, or the refrigerant level is low, cooling is not carried out efficiently.
For details, see “WHEN REQUIRED (4-21)“.
CLEANING AIR FILTER 3

If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop.
To prevent this, clean the air filter with compressed air once a week.
For details of the cleaning method, see “WHEN REQUIRED (4-21)“.
3-52
OPERATION OPERATION
OPERATION 3
CHECK BEFORE STARTING ENGINE, ADJUST 3
WALK-AROUND CHECK 3
Before starting the engine, look around and under the machine to check for loose nuts and bolts, or leakage of oil,
fuel, or coolant, and check condition of the work equipment and hydraulic system. Also check for loose wiring,
play, and accumulation of dust at places with high temperatures.
WARNING
q Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as
the engine muffler or turbocharger, may cause fire.
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
q Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to
slip and you cannot be seen from the operator's compartment. Always use the handrail and step at the
side when getting on or off the machine.
If the machine is at an angle, reposition it level before checking.
Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, and hoses.
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If
any problem is found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator.
Check for dirt accumulated around the engine and radiator. Also check for flammable material (dry leaves,
twigs, etc.) around the battery, engine muffler, turbocharger, or other high temperature engine parts. If any dirt
or flammable materials are found, remove them.
3. Checking engine for leak of water, oil and air
Check the engine for leak of engine oil, leak of water from the cooling system and leak of air from the suction
system. If any leak is found, repair it.
4. Check for oil leakage of oil from power train case, final drive case, hydraulic tank, hoses, and joints
Check that there is no oil leakage. If any problem is found, repair the place where the oil is leaking.
Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.
5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers.
If any problem is found, repair it.
3-53
OPERATION OPERATION
6. Check for problems in handrails, steps, loose bolts.
If any problem is found, repair it. Tighten any loose bolts.
7. Check for problems in gauges and monitor
Check that there is no problem in the gauges and monitor in the operator's cab. If any problem is found,
replace the parts. Clean off any dirt on the surface.
8. Check for damage to seat belt and mounting clamps (if equipped)
Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with
new parts.
CHECK BEFORE STARTING 3

Always check the items in this section before starting the engine each day.
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious
burns. Wait for the oil temperature to go down before performing this operation.
1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. The oil level should be between the H and L marks on dip-

stick (G).
If the oil level is below the L mark, add oil through oil filler
(F).
3-54
OPERATION OPERATION
5. When the oil level is higher than H, remove cover (1) in the
underpart of the truck.
6. Take the end of hose (2) out of the inspection window.
7. Loosen drain plug (P), drain excess oil and check the oil
level again.
8. If the oil level is correct, tighten the oil filler cap securely and close the engine side cover.
REMARK
If the machine is at an angle, reposition it to level before checking.
When checking the oil level after the engine has been operated, allow the engine to cool for 15 minutes before
checking.
CHECK DUST INDICATOR
1. Open engine side cover on the left side of machine.
2. Check if a yellow piston in the display of dust indicator (1)

has moved into the red area (7.5 kPa).
3. If the yellow piston has already moved into the red area
(7.5 kPa), either clean the filter element or replace it with
new one immediately.
For cleaning the filter element, refer to the section,

“CHECK, CLEAN AND REPLACE AIR CLEANER ELE-
MENT (4-21)“, in this manual.
4. After checking, cleaning, and replacing, press the knob of

dust indicator (1) to return the yellow piston to its original
position.
3-55
OPERATION OPERATION
CHECK, DRAIN WATER SEPARATOR
The water separator serves to separate moisture mixed in the

fuel.
1. Open up the engine side cover on the left side of the

machine.
The water separator is in one piece with fuel pre-filter (1)

and located in the lower part.
2. Through transparent cap (2), a water level and sediments,

if any, can be seen. When water and sediments have accu-
mulated, put a container beneath drain hose (3).
3. Loosen plug (4) to drain water and sediments.
4. When draining is finished, be sure to screw in plug (4).
Specified tightening torque: 0.2 to 0.45 N·m (0.02 to 0.046

kgf·m)
3-56
OPERATION OPERATION
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
q Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the
coolant in the sub-tank.
q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure. If the cap is removed to check the coolant level in this condition, there is a
hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pres-
sure before removing it.
1. Open up inspection cover (1) on the right side of the truck

to check if a cooling water level in sub-tank (2) remains
within the FULL - LOW range. If not, refill the tank with
clean water up to the FULL level through the filler port in
sub-tank (2).
REMARK
In summer, the coolant may overflow from the sub-tank drain
hose. This is no problem. It occurs because too much coolant
has been added.
2. After adding coolant, tighten the cap securely.
3. If the sub-tank is empty, check for leakage of coolant, then

add it to the radiator and sub-tank.
4. After adding coolant, close the engine side cover.
3-57
OPERATION OPERATION
CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL
WARNING
The parts and oil are at high temperature after the engine
is stopped, and may cause serious burns. Wait for the tem-
perature to go down before starting the operation.
1. Open cover on the right side of the machine.
2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. The oil level should be between the (H) and (L) marks on
dipstick (G).
If the oil level is below the (L) mark, add oil through oil filler
(F).
5. If the oil level is above the H mark, remove cover (1) on the
bottom of the machine.
Loosen drain plug (P), drain the excess oil, then check the
oil level again.
6. If the oil level is correct, insert dipstick (G) fully into the dip-
stick guide again.
REMARK
If the machine is at an angle, reposition it to level before check-
ing.
When checking the oil level after the engine has been oper-
ated, allow the engine to cool for 15 minutes before checking.
CHECK ELECTRIC WIRING
CAUTION
If the circuit breakers are activated and the fuses are blown frequently or there is a trace of short-circuit-
ing in the wirings, check the cause immediately and either correct it by yourself or call your Komatsu dis-
tributor for the repair.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap to clear the breather hole.
Check that the circuit breakers are in normal condition (with the red button pushed in), that the fuses have no dam-
age and fuses of the specified capacity are in use and that there is no trace of disconnection or short-circuiting in
the wirings and no damage in the covers. Moreover check the terminals for loosening and retighten loosened one,
if any.
Be particularly careful to check the wiring for the battery, starting motor, and alternator.
In addition, if any flammable material is accumulated around the battery, remove it.
For repairs or investigation of the cause, please contact your Komatsu distributor.
3-58
OPERATION OPERATION
CHECK BRAKE PEDAL TRAVEL
WARNING
If the brake pedal stroke is not 70 to 90 mm (2.8 to 3.5 in) (below 70 mm or over 90 mm), the brake and
steering force is too strong or insufficient. If the stroke is 91 mm or longer, adjust it.
1. Depress the brake pedal all the way until it stops.
2. Check that the distance of travel (A) at the center of the

pedal is 70 to 90 mm.
3. When this value exceeds 91 mm, or the brake fails to work,

please contact your Komatsu distributor for adjustment.
CHECKING WITH MACHINE MONITOR
1. Turn starting switch (1) to the ON position (B).
2. Check that all the monitors and gauges light up for approx.
2 seconds and the alarm buzzer sounds for approx. 2 sec-
onds.
REMARK
If the lamps do not light up, there may be a failure or discon-
nection in the monitor, please contact your Komatsu distributor.
3-59
OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When adding fuel, never spill the fuel or let it overflow. It will cause fire.
If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
Fuel is highly flammable and dangerous. Never bring flames near fuel.
1. Turn the engine starting switch to the ON position and

check the fuel level gauge (G) on the monitor panel for fuel
level.
After checking, turn the switch back to the OFF position.
2. After completing work, fill the fuel tank through fuel filler
port (F).
Fuel capacity: 415 liters
3. After adding fuel, tighten the cap securely.
REMARK
When dozing on a grade, make sure there is plenty of fuel in
the tank so that the engine fuel line does not become aerated.
If breather hole (1) on the cap is clogged, the pressure in the
tank will drop and fuel will not flow.
Clean the hole from time to time.
CHECK HORN SOUND
Check that the horn sounds. If it does not sound at all or the sound is extremely feeble, a defect or broken wire is
suspected, ask your Komatsu distributor for possible repairs.
1. Turn starting switch to the ON position (B).
3-60
OPERATION OPERATION
2. Push the horn switch and check that the horn sounds.
CHECK THAT LAMPS LIGHT UP
Check that the head lamp, rear lamp, additional working lamp (if equipped), and instrument lamp light up normally
and they are free from stain and damage.
If the lamps do not light, check for a broken bulb or disconected wire, contact your Komatsu distributor for repairs.
2. Turn the Head lamp and Rear lamp switches to the l posi-
tion (ON), and check that all the lamps light up.
CHECK OF OPERATION OF BACKUP ALARM
Check that the backup alarm sounds normally. If it does not, a defect or broken wire is suspected, ask your
Komatsu distributor for possible repairs.
3-61
OPERATION OPERATION
2. Set the steering, forward-reverse, gear shift lever in the

REVERSE position (R).
The alarm must sound immediately at this time. The alarm

keeps sounding until the steering, forward-reverse, gear
shift lever is set to the NEUTRAL position (N) or FOR-
WARD position (F).
ADJUSTMENT 3
ADJUST OPERATOR'S SEAT
WARNING
When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK
position to prevent any accidental contact with the control levers.
q Always adjust the operator's seat before starting each operation or when the operators change shift.
q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal
can be fully depressed.
(A) Fore-and-aft adjustment
Pull lever (1), set the seat to a position where it is easy to oper-
ate, then release the lever.
Fore-aft adjustment: 160 mm (8 stages)
(B) Weight adjustment of seat
Turn knob (2) under the seat to match the weight adjustment
scale with your own weight.
The weight can be adjusted to 50 to 120 kg.
REMARK
If you want to make the seat softer, turn the weight adjustment
to a lower weight; if you want to make the seat harder, adjust to
a higher weight. When operating on uneven surfaces, adjust
the seat to a harder setting.
(C) Adjust reclining angle
Pull up lever (3) and set the seat back to a position which is
comfortable for operation, then release the lever.
Sit with your back against the seat back when adjusting. If your
back is not touching the seat back, the seat back may suddenly
move forward.
3-62
OPERATION OPERATION
REMARK
The seat can be reclined more when the seat is pushed to the front. The amount of reclining decreases as the seat
is pushed back, so when moving the seat back, return the seatback to the upright position.
(D) Seat angle adjustment
q Front angle adjustment of seat (5 stages)
To raise the front of the seat, apply your weight to the seatback, while pulling up lever (4).
To lower the front of the seat, apply your weight to the front of the seat, while pulling up lever (4).
q Rear angle adjustment of seat (5 stages)
To raise the rear of the seat, stand up on your feet a little, while pulling up lever (5).
To lower the rear of the seat, apply your weight to the rear of the seat, while pulling up lever (5).
(E) Seat height adjustment
Pull up levers (4) and (5) alternately to adjust the angle of the seat.
Then, release the levers to lock the seat.
(Height adjustment distance: 5 stages, 60 mm)
FASTENING AND REMOVING SEAT BELT
(If equipped)
WARNING
q Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there
is any wear or damage, replace.
q Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The
date of manufacture is woven on the reverse side of the belt.
q Adjust and fasten the seat belt before operating the machine.
q Always use the seat belt when operating the machine.
q Do not use the seat belt with either half of the belt twisted.
Check that the bolts of the clamp securing the belt to the chassis are not loose. Tighten them if they are loose.
The tightening torque for the mounting bolt is 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m).
If the belt surface is scratched or frayed or if the fittings are broken or deformed, replace the seat belt unit.
3-63
OPERATION OPERATION
FASTENING AND REMOVING SEAT BELT
1. After adjusting the seat position, adjust tether belt (1).

Tense the tether belt and install it when there is no one sit-
ting on the seat.
2. Sit on the seat and hold tongue (4) connected to wind-in

mechanism (2) and pull out the belt slowly so that the belt
will cover your abdomen sufficiently.
3. Insert tongue (4) in buckle (3) until it clicks. The belt is

pulled back into wind-in mechanism (2) until it is fitted to
your abdomen. The belt is locked under this condition and
cannot be extended anymore. Fit the belt to your abdomen
without twisting it.
REMARK
If the belt is locked before the tongue is inserted in the buckle,
let it return to the wind-in mechanism, then repeat the above
procedure from the start.
4. Pull the belt to check that it is securely locked in position.
5. When removing the belt, press the red button on buckle (3).
The belt will automatically retract.
ADJUST MIRROR
(If equipped)
Loosen nut (1) of the mirror and adjust the mirror to a position
where it gives the best view from the operator's seat.
In particular, be sure to adjust the mirror so that people at the

rear left or right of the machine can be seen clearly.
ADJUST LEFT CONSOLE BOX
WARNING
q Before adjusting the position of the left console box, always set the parking brake lever to the LOCK
position.
q After adjusting the position of the left console box, push and pull the console box to the front and rear
to check that it is locked and cannot move. If it is not locked properly, the console box may suddenly
move during operations, causing misoperation of the steering, forward-reverse, gear shift lever, and
resulting in failure.
The left console box can be adjusted by 90 mm in 9 stages to the front or rear. Adjust it to the most suitable posi-
tion to match the adjustment of the operator's seat.
3-64
OPERATION OPERATION
1. Pull up lock lever (2) at the rear of console box (1) at the
left side of the operator's seat, and set the lock lever to the
FREE position.
NOTICE
Do not grip the steering, forward-reverse, gear shift lever
when removing console box (1). There is danger that the
lever may break.
2. With the lock lever (2) pulled up, use your other hand to
grip the front of console box (1), then move it to the front or
rear with your left and right hands.
3. Move console box (1) to the desired position until a click is

heard. Then pull up lock lever (2) and release it. Lock
lever (2) automatically returns to LOCK position (L).
ADJUST ARMREST
The height of the armrest on the left and right sides of the operator's seat can be adjusted to 3 positions. After
adjusting the operator's seat, adjust the armrest to a suitable height.
ADJUST ARMREST (RIGHT)
Arm rest (1) can be adjusted in three stages; 30 mm upward and 25 mm downward from standard height (B).
1. Loosen knob (2) (2 places).
2. Move the armrest on the operator's seat to the front, then

align the position of the 3 holes ((A), (B),(C)).
3. Return the armrest to the rear.
4. Tighten knob (2) securely.
3-65
OPERATION OPERATION
ADJUST ARMREST (LEFT)
The height of the armrest on the left side of the operator's seat can be adjusted steplessly up and down 60 mm
together with the console box.
Turn up/down left adjustment knob (1) to adjust the height.

Turn the knob to adjust as follows.
Turn CLOCKWISE to move DOWN
Turn COUNTERCLOCKWISE to move UP
OPERATION AND CHECK BEFORE STARTING ENGINE 3
WARNING
When starting the engine, check that the parking brake lever and work equipment lock lever are placed
securely at the LOCK position.
If the work equipment control lever is touched by accident when the engine is started, the work equipment
may move unexpectedly and cause serious injury or damage.
3-66
OPERATION OPERATION
1. Check that parking brake lever (1) is in the LOCK position

(L).
REMARK
If this parking brake lever is not in the LOCK position, the
engine will not start.
2. Check that steering, forward-reverse, gear shift lever (2) is

in the NEUTRAL position (N).
REMARK
The engine cannot be started if steering, forward-reverse, gear
shift lever (2) is not in the NEUTRAL position.
If steering, forward-reverse, gear shift lever (2) is in FORWARD
or REVERSE, the letter P on display panel A will flash.
3. Check that the blade is lowered to the ground and that

blade control lever (3) is in the HOLD position (B).
4. Check that the work equipment lock lever (4) is LOCK posi-
tion (L).
3-67
OPERATION OPERATION
STARTING ENGINE 3
NORMAL STARTING 3
WARNING
q Sit down in the operator's seat before starting the engine.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may
cause serious bodily injury or fire.
q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start
the engine.
q Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.
NOTICE
q Do not continue to crank the starting motor continu-
ously for more than 60 seconds under any circum-
stances. If the engine does not start, wait for at least 2
minutes, then repeat the procedure from Step 2.
q Before starting the engine, check that the fuel control

dial is at the low idle (MIN) position.
q The machine is equipped with a function to automati-

cally warm up engine cooling water temperature more
quickly and another function to protect the turbo-
charger. In a cold weather startup, the engine revolu-
tion may not change for several seconds immediately
after the startup even if fuel control dial (1) is operated.
q If the fuel control dial is in the FULL position, the

engine will accelerate suddenly and cause damage to
the engine parts, so set it to an intermediate or low
speed position.
1. Turn fuel control dial (1) from the low idle (MIN) position to
a slightly higher speed.
3-68
OPERATION OPERATION
2. Insert the key into starting switch (2) and turn the key to the
START position (C). The engine will start.
3. When the engine starts, release the key in starting switch

(2). The key will return automatically to the ON position (B).
3-69
OPERATION OPERATION
STARTING IN COLD WEATHER 3
WARNING
q Start the engine only after sitting down in the operator's seat.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may
cause a serious bodily injury or fire.
q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start
the engine.
q Never use starting aid fluids as they may cause explosions.
q Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.
NOTICE
q Do not continue to crank the starting motor continu-
ously for more than 60 seconds under any circum-
stances. If the engine does not start, wait for at least 2
minutes, then repeat the procedure from Step 2.
q Before starting the engine, check that the fuel control

dial is at the low idle (MIN) position.
q The machine is equipped with a function to automati-

cally warm up engine cooling water temperature more
quickly and another function to protect the turbo-
charger. In a cold weather startup, the engine revolu-
tion may not change for several seconds immediately
after the startup even if fuel control dial (1) is operated.
q If the fuel control dial is in the FULL position, the

engine will accelerate suddenly and cause damage to
the engine parts, so set it to an intermediate or low
speed position.
1. Turn fuel control dial (1) to the center position between MIN
and MAX position.
3-70
OPERATION OPERATION
2. Insert the key into starting switch (2) and turn the key to the
ON position (B).
3. Check that engine pre-heating pilot lamp (3) on the monitor

panel lights up.
4. Maintain the key in the on position until the pre-heating

pilot lamp (3) goes off.
5. When preheating pilot lamp (3) goes off, turn the key of ignition switch (2) to the START position (C) to crank
the engine.
The time that preheating pilot lamp (3) stays on changes according to the ambient temperature as shown in
the table below.
Ambient temperature Pre-heat time

-3°C to -10°C 5 to 15 seconds
6. When the engine starts, release the key in starting switch

(2). The key will return automatically to the ON position (B).
REMARK
Immediately after an engine startup, keep the engine idling, and while the engine is idling, keep the foot off the
deceleration pedal and do not operate the work equipment.
7. When the engine rotation stabilizes, return to the low idle (MIN) position of fuel control dial (1) and then carry
out the warming-up operation.
3-71
OPERATION OPERATION
REMARK
Regardless of the ambient temperature, if the key in starting switch (2) is turned from OFF position to left, preheat-
ing pilot lamp (3) will light up and preheating will start. (Preheating continues while the starting switch is held at the
left.)
For the details of the preheating time, see the table in Step 5.
While preheating is being carried out, the preheating pilot lamp (3) lights up to show that preheating is being car-
ried out.
If the engine does not start with the above operation, wait for about 2 minutes, and repeat steps 3. And 4.
The relationship between the actuation time of the turbo protect function and the engine coolant temperature is as
follows.
Even if the fuel control dial is operated within the time given below, the engine speed will not change.
Turbo protect function
The turbo protect function is a function to protect the turbocharger by keeping the engine speed at less than 1000
rpm immediately after the engine is started.
When the turbocharger protection function and engine cooling water auto warming-up function are activated at the
same time, the former takes priority over the latter.
q While the turbocharger protection function is in operation, the engine revolution is held at 1000 rpm even if the
fuel control dial is set at above 1000 rpm.
fuel control dial is operated.
q When the turbo protect function is canceled, the engine speed is set to the speed for the position of the fuel
control dial.
q The relationship between the length of time of actuating the

turbo protect function and the temperature of the engine Coolant Turbo protect
coolant is as shown in the next table. temperature time (sec.)
Above 10°C 0
10 to -30°C Change 0 to 20
Engine Cooling Water Auto Warming-up Function
This is a function to automatically warm up engine cooling water more quickly by raising an engine idling speed.
When the turbocharger protection function and engine cooling water auto warming-up function are activated at the
same time, the former takes priority over the latter.
fuel control dial is set at any rpm. However, if the fuel control dial is held at the engine full speed (MAX) for
more than three seconds, the engine will gradually pick up the speed up to the full idling.
q This function continues to work for a maximum of 10 minutes, or until the engine cooling water temperature
reaches 30°C.
q If the deceleration pedal is depressed while this function is in operation, the engine rpm goes down below
1200 rpm.
3-72
OPERATION OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3
WARNING
q If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position.
q If the work equipment is operated without warming the machine up sufficiently, the response of the
work equipment to the movement of the control lever will be slow and the work equipment may not
respond as the operator desires, so always carry out the warming-up operation. Particularly in cold
areas, be sure to carry out the warm-up operation completely.
WARMING UP OPERATIONS 3
NOTICE
Avoid abrupt acceleration until warm-up run is completed.
Do not run the engine at low idle or high idle for more than
20 minutes.
If it is necessary to run the engine at idle, apply a load or
run at a medium speed from time to time.
1. Turn fuel control dial (1) to the mid point between the low
idling speed (MIN) and full speed (MAX) to start up the
engine.
REMARK
The machine holds an engine revolution at 1200 rpm by means
of its engine cooling water warming-up function until after the
engine cooling water temperature reaches 30°C.
For more details on this function, see “STARTING IN COLD
WEATHER (3-70)“.
2. After warm-up is completed, check gauges and caution

lamps for proper operation. If any problem is found, repair
it.
Continue to run the engine under a light load until engine

coolant temperature gauge indicator (2) is within the green
range (B).
(A): White range
(B): Green range
(C): Red range
3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu dis-
tributor.
3-73
OPERATION OPERATION
STARTING IN COLD WEATHER 3

(Ambient temperature below 10°C)
NOTICE
q When the hydraulic oil is at a low temperature, do not
carry out operations or move the levers suddenly.
Always carry out the warm-up operation. This will help
to extend the machine life.
Do not suddenly accelerate the engine before the
warm-up operation is completed.
q Do not run the engine at low idle or high idle con-tinu-

ously for more than 20 minutes. This will cause leak-
age of oil from the turbocharger oil supply piping.
If it is necessary to run the engine at idle, apply a load
from time to time or run the engine at a mid-range
speed.
1. Turn fuel control dial (1) to the mid point between the low
idling speed (MIN) and full speed (MAX) to start up the
engine.
REMARK
The machine holds an engine revolution at 1200 rpm by means
of its engine cooling water warming-up function until after the
engine cooling water temperature reaches 30°C.
For more details on this function, see “STARTING IN COLD
WEATHER (3-70)“.
2. Blade control lever (2) to the full RAISE position, then hold
the lever in position, and operate slowly to the left tilt relief
and right tilt relief positions for 5 minutes.
3. Then operate blade control lever (2) to the full RAISE posi-
tion (up to the lever stroke end) and hold it in that position;
alternate the right and left TILT relief intermittently; lower
the blade to the ground by operating the control lever to the
LOWER position; operate the control lever to the FLOAT
position (up to the lever stroke end); and alternate right and
left TILT relief intermittently for five minutes.
4. Lower the blade to the ground, move the control lever fully (A) RAISE (D) FLOAT
to the FLOAT position (lever stroke end) and hold the lever (B) HOLD (E) LEFT TILT
in position for 1 minute. Next, release the lever and check (C) LOWEW (F) RIGHT TILT
that it stays in the FLOAT position. After waiting for 3 min-
utes, return the lever to the HOLD position.
3-74
OPERATION OPERATION
5. After warm-up run is completed, check gauges and caution

lamps for proper operation. If any abnormality is found,
repair it.
q Continue to run the engine at light load until engine

coolant temperature gauge indicator (3) and Hydraulic
oil temperature gauge (4) fall within the green range
(B).
(A): White range
(B): Green range
(C): Red range
REMARK
If the oil temperature in the power train is not raised properly, it will take longer to accelerate to the maximum
speed.
6. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu dis-
tributor.
STOPPING ENGINE 3
NOTICE
If the engine is abruptly stopped before it has cooled
down, engine life may be drastically shortened. Do not
abruptly stop the engine except for an emergency.
If the engine has overheated, do not stop it abruptly, run it
at medium speed allowing the engine to gradually cool
down, then stop it.
1. Lower the work equipment to the ground.
2. Place fuel control dial (1) in the low idle (MIN) position and
run the engine at low idle speed for about 5 minutes to
allow it to gradually cool down.
3-75
OPERATION OPERATION
3. Turn the key in ignition switch (2) to the OFF position (A).
The engine will stop
REMARK
When engine starting switch (2) key is turned to the OFF posi-
tion, the engine stops, but the machine's main power source is
not turned off immediately.
This is a time lag provided for the controller to memorize the
operation status and then terminate the system. While this pro-
cess continues, the main power is maintained. The power hold-
ing time varies depending on the operation condition.
Also when the cooling fan is used for a cleaning purpose, the
machine's main power source is not turned off immediately,
even if engine starting switch (2) key is turned to the OFF posi-
tion.
This time lag is provided to protect the hydraulic circuit, and in
this case, the machine's main power is maintained for seven
seconds.
4. Remove the key from starting switch (2).
3-76
OPERATION OPERATION
MACHINE OPERATION 3
MOVING MACHINE 3
WARNING
q When moving the machine, check that the area around
the machine is safe, and sound the horn before mov-
ing.
Do not allow anyone to enter the area around the
machine.
There is a blind spot at the rear of the machine, so be
particularly careful when traveling in reverse.
q When moving the machine on a slope, always keep

brake pedal (7) depressed even after releasing parking
break lever (1).
q When moving the machine up a steep slope, turn fuel

control dial (4) to the max. position, and keep brake
pedal (7) and deceleration pedal (5) depressed. Then
move joystick (steering, directional, and gearshift
lever) (6) from the N position to the direction of travel
and release brake pedal (7) slowly. When the travel
speed rises, release deceleration pedal (5) slowly.
1. Operate parking brake lever (1) to the FREE (F) position.
2. Operate work equipment lock lever (2) to the FREE (F)

position.
3-77
OPERATION OPERATION
3. Put blade control lever (2) in the RAISE position (R) to

raise the blade 40 to 50 cm off the ground.
4. Turn fuel control dial (4) to the full speed (MAX) position,
and fully depress decelerator pedal (5).
5. Operate steering - forward / reverse shifting - gearshift

lever (6) to the FORWARD (F) position or REVERSE (R)
position and gradually release deceleration pedal (5).
REMARK
Check that the backup alarm buzzer (rear side warning buzzer) properly sounds, when steering - forward / reverse
shifting - gearshift lever (6) is operated to the REVERSE (R) position. If it does not, call on your Komatsu distribu-
tor for repairs.
3-78
OPERATION OPERATION
STOPPING MACHINE 3
WARNING
Avoid stopping suddenly. Give yourself ample room when
stopping.
1. Depress brake pedal (1) to stop the machine.
NOTICE
If the brake is depressed when the engine speed or travel
speed is high, the brake disc may make a slipping sound.
Normally, depress decelerator pedal (2) to reduce the
engine speed and travel speed before depressing the
brake.
2. Move steering, forward-reverse, gear shift lever (3) to the

NEUTRAL position (N), depress brake pedal (1) further,
and stop the machine.
SHIFTING GEARS 3
The machine does not have to be stopped to shift gears.

desired gear position to shift gears.
3-79
OPERATION OPERATION
GEARSHIFTING OPERATION 3
When UP switch (U) or DOWN switch (D) is pushed, the trans-
mission speed will change.
UP switch (U): Each time the switch is pressed, the transmis-

sion will up shift one speed.
DOWN switch (D): Each time the switch is pressed, the trans-
mission will down shift one speed.
There are 3 forward and 3 reverse speed ranges.
For details of the maximum speed in each speed range, see

“SPECIFICATIONS (5-2)“.
REMARK
The present speed range is displayed in the center of display
panel A (2).
1st: 1 is displayed
2nd: 2 is displayed
3rd: 3 is displayed
If the machine has failed, the speed range and speed range
display may change automatically.
GEARSHIFTING OPERATION USING PRESET MODE FUNCTION 3

If the preset mode function is used, the speed ranges used when the machine travels in forward and reverse can
be preset as desired.
1. Set steering, forward-reverse, gear shift lever (1) to the

NEUTRAL position (N).
2. When preset mode switch (3) is set to the l position (ON),

the function is actuated.
3-80
OPERATION OPERATION
3. When the preset mode function is actuated, [F1-R1] is dis-

played at the left side of the bottom line of display panel B
(multi-information) on the monitor panel, and the [F1-R1]
mode is set.
REMARK
When preset mode switch (3) is set to the ON position (a), the
default [F1-R1] mode is set.
4. If it is desired to select another mode, press UP switch (U) or DOWN switch (D) on steering, forward-reverse,
gear shift lever (1) and display the desired mode on control panel B (multi-information).
The types of mode and method of selection are as follows.
up up up up
→ → → →
[F1-R1] [F1-R2] [F2-R1] [F2-R2] [F2-R3]
← ← ← ←
down down down down
q Example of shift control when [F2-R2] mode is set.
When steering, forward-reverse, gear shift lever is set to F position, speed range F2 is automatically selected.
When steering, forward-reverse, gear shift lever is set to R position, speed range R2 is automatically selected.
REMARK
Even when the preset mode function is being actuated, it is possible to select the speed range by operating the UP
switch or DOWN switch when the machine is traveling forward or in reverse.
However, the preset mode remains set as it is. If the steering, forward-reverse, gear shift lever is returned to the
NEUTRAL position and then operated again to the FORWARD or REVERSE position, the set speed range is
selected.
A particular advantage is that when the auto shift down function described below is being actuated, it is possible to
save the trouble of shifting up when traveling in reverse after the transmission has shifted down during digging.
3-81
OPERATION OPERATION
AUTO DOWN SHIFT OPERATION 3

If the travel speed drops because of the load conditions when
traveling, this function automatically down shifts to a lower
speed range.
1. The function is actuated when auto shift down switch (4) on

the front panel is set to l position (ON).
Q (OFF) position: Canceled
The transmission is automatically shifted down F2→ F1, F3

→ F2, R2 → R1, R3 → R2.
REMARK
While the preset mode is in operation, it is designed the way
the machine does not automatically shift up for a safety reason,
even after it automatically shifts down.
To shift up, press UP (U) button manually.
However, the preset mode setting remains the same. The
machine returns to the set travel speed when the steering - for-
ward / reverse shifting - gearshift lever is once operated to the
neutral position and then either to the FORWARD or to the
REVERSE position again.
3-82
OPERATION OPERATION
SHIFTING BETWEEN FORWARD AND REVERSE 3
WARNING
When switching between FORWARD and REVERSE, first check that the direction of travel is safe.
CAUTION
The travel direction can be changed without stopping the
machine. Do not change it while the engine is running at
the full speed, however, but depress the decelerator pedal
to lower the engine speed before changing the travel
direction for safety, comfort, and longer life of the power
train.
1. Depress decelerator pedal (1) to reduce the engine speed.

NEUTRAL position (N), reduce the speed, then depress
brake pedal (3) and stop the machine.
3. After depressing decelerator pedal (1), move steering, for-

ward-reverse, gear shift lever (2) to the desired position.
Position (F): Forward
Position (N): Neutral
Position (R): Reverse
REMARK
Check that the backup alarm buzzer (rear side warning buzzer)
properly sounds, when the steering - forward / reverse shifting -
gearshift lever is operated to the REVERSE (R) position. If it
does not, call on your Komatsu distributor for repairs.
3-83
OPERATION OPERATION
4. Release decelerator pedal (1) and raise the engine speed.
REMARK
If the forward- reverse control lever is shifted when the machine is traveling downhill, a directional change may
automatically take place via 1st gear for safety. For example, when the forward- reverse control lever is shifted
from F2 to R2, the directional change may take place in the sequence of F2 to R1 to R2.
3-84
OPERATION OPERATION
STEERING MACHINE 3
WARNING
q Avoid as much as possible turning the machine on a slope.
The machine will tend to slip sideways. Particular care should be taken on soft or clay soil.
q Never make a pivot turn at high speed.
NORMAL TURNING 3
WARNING
When performing a counterrotation turn, the feeling of operation when your head is facing the rear is dif-
ferent from the feeling if you are facing the front. Never carry out a counterroatation turn while facing the
rear.
To turn the machine while traveling, incline steering, forward-

reverse, gear shift lever (1) in the direction of the turn.
TURNING LEFT WHILE TRAVELING FORWARD
NOTICE
If the lever is moved partially to the forward or reverse
position and then is moved in the direction of turn, the
machine may carry out a counterrotation turn, so operate
the lever fully to the forward or reverse position.
If steering, forward-reverse, gear shift lever (1) is moved to the

FORWARD position (F) and moved partially to the left (L), the
machine will start to turn gradually. After that, the lever can be
moved further towards the end of its travel to set the desired
turning radius.
REMARK
To turn gradually to the right while traveling forward, if the
steering, forward-reverse, gear shift lever (1) is operated to the
FORWARD position (F) and moved slowly to the right, the
machine will start to turn gradually. After that, the lever can be
moved further towards the end of its travel to set the desired
turning radius.
3-85
OPERATION OPERATION
WHEN MAKING PIVOT TURN TO LEFT WHILE TRAVELING
NOTICE
When carrying out a counterrotation turn, if the load is not
equal on the left and right sides, the machine may carry
out a pivot turn, so check the ground conditions and be
careful not to hit any obstacles.
With steering, forward-reverse, gear shift lever (1) in the NEU-

TRAL position (N), operate the lever partially to the left (L).
The left and right tracks will rotate in opposite directions, and
the machine will make a slow counterrotation turn. If the lever
is moved further, the speed of the counterrotation turn will
increase.
REMARK
When making a right counterrotation turn, move the steering,
forward-reverse, gear shift lever (1) to the right (R) in the same
way.
PRECAUTIONS FOR OPERATION 3
PAY ATTENTION TO GAUGES 3

When the red range lights on the power train oil temperature gauge while operating, reduce the load and wait for
the temperature to decrease.
PERMISSIBLE WATER DEPTH 3

When operating in water, always keep the bottom of carrier roll-
ers (1) above the surface of the water. Also, be careful that the
engine cooling fan will not come in contact with water. The fan
can be damaged.
After using the machine in the water for a long time, grease the
work equipment and equalizer bar through each grease fitting.
For more details on the lubrication method, see “LUBRICAT-

ING (4-44), GREASE EQUALIZER BAR SIDE PIN (4-45) and
GREASE EQUALIZER BAR CENTER PIN (4-46)“.
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS 3
METHOD OF USING DECELERATOR PEDAL
When stepping on the decelerator pedal while going uphill, climbing ability will be reduced and the machine will
stop.
Furthermore, the engine may stall.
3-86
OPERATION OPERATION
USE ENGINE AS BRAKE
When going downhill, move steering, forward-reverse, gear shift lever into low speed to run engine at slow speed
and travel down slope using the engine as a brake.
Do not move the steering, forward-reverse, gear shift lever to the NEUTRAL position.
When traveling down hills of more than 15°, shift down to 1st speed (R1 or F1).
BRAKING WHEN TRAVELING DOWNHILL
While descending a slope using the engine as a brake, also apply the brakes.
Failure to brake may result in overrunning, causing engine trouble.
PRECAUTIONS ON SLOPES 3
BE CAREFUL OF FUEL LEVEL
If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the
angle of the machine or the swaying of the machine. If this makes the engine stop, the braking effect will be
reduced, so be careful not to let the fuel level in the fuel tank become too low.
BE CAREFUL OF OIL LEVEL
When operating machine on sloped areas of more than 20°, fill all appropriate components with oil to H level.
PRECAUTIONS WHEN ENGINE STOPS ON SLOPES
If the engine stops while working or traveling on a hill, immediately depress the brake pedal to bring the machine to
a complete stop.
METHOD OF USING BRAKES 3

The following actions cause premature damage to the brakes, so avoid such operations.
q Using emergency brake at full speed
q Using brake with engine running at full speed in first gear (F1, R1) (Machine stall condition)
REMARK
Always depress the decelerator pedal to lower the engine speed before actuating the brakes.
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS 3

Always keep the door closed when traveling or carrying out operations.
If the door is open, there is danger of damage from obstacles or strong vibration.
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT
THE VIEW 3
q For safety reasons, do not install anything on the cab glass that will obstruct the view.
q Always keep the glass clean to ensure safety during operations.
3-87
OPERATION OPERATION
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES 3

WARNING
The cab structure may cause blind spots.
When operating, always be sure to check carefully that
there is no obstacle or worker in the surrounding area.
WORK POSSIBLE USING BULLDOZER 3

In addition to the following, it is possible to further increase the range of applications by using various attachments.
DOZING 3
A bulldozer digs and transports dirt in a forward direction.
Slope excavation can always be most effectively carried out by
proceeding from the top downward.
When dozing toward one side only, operate with angled blade
(angledozer only).
3-88
OPERATION OPERATION
SMOOTHING 3
NOTICE
Avoid smoothing on rocky or stony ground. It can damage the blade.
To finish the ground to a flat surface after digging or leveling,

put a full load of soil in front of the blade and operate the blade
up and down in small movements while traveling forward.
Finally, place the blade at FLOAT and travel at low speed in
reverse while pulling the blade over the ground surface. Before
doing this, hold the lever by hand at the FLOAT position for at
least 1 second to make sure that it stays in position. To prevent
damage to the blade, be careful not to travel over any stones or
rocks.
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING 3

For digging and ditch excavation of hard or frozen ground, tilt
the blade. Even hard ground can be dug effectively by a tilted
or angled blade.
FELLING TREES, REMOVING STUMPS 3

NOTICE
Do not uproot trees or stumps or fell trees by angling or tilting the blade.
For trees with a diameter of 10 to 30 cm, raise the blade high

and push 2 or 3 times to fell the tree.
Next, travel in reverse, and dig the corner of the blade into the
ground to cut and dig up the roots.
When doing this, never hit the tree at high speed or apply
shock to fell the tree.
3-89
OPERATION OPERATION
ADJUSTING POSTURE OF WORK EQUIPMENT 3
ADJUST ANGLE OF BLADE EDGE 3
WARNING
It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge. Set the
work equipment in a stable condition, then stop the engine and lock the work equipment securely with the
work equipment lock lever.
Blade cutting edge angle (A) can be adjusted to meet soil conditions.
POWER TILTDOZER
Power tiltdozer with screw-adjustable tilt brace.
Turn the brace with bar handle (1) to extend a distance

between the joints (B), and then blade cutting edge angle (A)
increases. To decrease the angle, shorten the distance.
Standard blade cutting edge angle (A) is 55°.
Standard distance between the joints (B) is as shown below.
D65EX: 1150 mm
D65PX: 1146 mm
D65WX: 1150 mm
REMARK
When the machine is installed with a fixed type tilt brace, a blade cutting edge angle cannot be adjusted.
When the blade cutting edge is held at the standard angle, the tilt amount is as shown below.
D65EX: 460 mm
D65PX: 450 mm
D65WX: 410 mm
ANGLEDOZER
The angle of the blade edge of the angledozer cannot be adjusted.
Standard distance between the joints (B) is as shown in the table below.
Model Standard Use Range

D65EX 1127mm 1117-1137mm
D65PX 1096mm 1086-1106mm
3-90
OPERATION OPERATION
ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT 3

1. When assembling the work equipment, adjust an amount of play at each part (C) to the right values shown in
the following table.
Shim adjusting
(1) (2) (3) (4)
position
Tilt Lift Center Trunnion
Item
Optimum
mm 0.2 - 0.5 0.2 - 0.5 0.2 - 0.5 0.2 - 1.0
value
Thickness of
standard mm 5 4 5 10
shims
2. After the assembly, grease shim adjusting positions (1) to (3) and check that each part turns smoothly.
ADJUSTING TENSION OF CENTER BRACE 3

(Power tiltdozer only)
(Powertilt, Power pitch dozer only)
In case the work equipment assembly is disassembled for transportation and reassembled at a worksite, tension
of the center brace has to be adjusted anew. Otherwise the bushing at the connecting part of blade and straight
frame will likely slip off, allowing sand and dirt to enter the bushing, which eventually leads to premature wear or
damage of the bushing. Make this adjustment as follows:
WARNING
Except when operating the blade in Step 4, always lock the blade control lever securely with the work
equipment lock lever.
1. Adjust with shim (2) so that the play of ball joint (1) is 0.2 to
0.5 mm.
2. Loosen bolt (3).
3. Install the blade assembly.
4. Operate the blade control lever to float the blade.
5. Insert bar (4) in the center brace hole and turn the bar to
the protruding side. At that time, adjust clearance between
the track shoe and frame (D) so that it is equal on the right
and left sides.
Rotating torque: 24.5 to 49 N·m (2.5 to 5 kgf·m) (Blade at

FLOAT)
Standard distance between the joints (B) is as shown

below.
D65EX: 995 mm
D65PX: 992 mm
D65WX: 995 mm
6. Tighten bolt (3).
Tightening torque: 490.3 to 608 N·m (50 to 62 kgf·m)
3-91
OPERATION OPERATION
ADJUST AMOUNT OF TILT 3
ANGLEDOZER
WARNING
When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake. Set the work
equipment in a safe condition, then stop the engine and lock the work equipment securely with the work
equipment lock lever.
NOTICE
An amount of tilt (A) can be increased to a maximum of
400 mm.
Adjust an amount of tilt (A) within 400 mm.
1. Raise the blade up to the height of 400 mm to 500 mm

above the ground, and put block (B) beneath the blade
edge.
2. Loosen the bolt (1) of the brace, insert a suitable bar into
hole (2) of the brace, and turn it.
REMARK
When turning the brace with bar, keep the blade above the
ground.
Right tilt: Make right side shorter, left side longer
Left tilt: Make left side shorter, right side longer
3. Tighten set bolt (1).
3-92
OPERATION OPERATION
METHOD OF ANGLING BLADE 3

Angledozers only
When dozing toward one side only, operate with angled blade.
WARNING
q When adjusting the amount of angling, it is dangerous
if the work equipment is moved by mistake. Set the
work equipment in a safe condition, then stop the
engine and lock the work equipment securely with the
work equipment lock lever.
q Be careful when removing arm (2). After arm (2) is

removed, the blade can move freely.
(I) Left angle : 25°

(J) Right angle: 25°
1. Raise the blade up to the height of 400 mm to 500 mm

above the ground, and put block (B) beneath the blade
edge.
2. Remove pins (1) on the left and right sides, then remove
arm (2) from the frame.
3. Insert arm (2) into any desired bracket (C) on the frame
(three brackets provided on one side) and fasten it with pin
(1) so that it does not slip off.
3-93
OPERATION OPERATION
PARKING MACHINE 3
WARNING
q When stopping the machine, select flat hard ground
and avoid dangerous places.
If it is unavoidably necessary to park the machine on a
slope, place the parking brake lever in the LOCK posi-
tion and insert blocks underneath the track shoes. As
an additional safety measure, thrust the blade into the
ground.
q If the work equipment control lever is touched by acci-

dent, the work equipment may move suddenly, and
this may lead to a serious accident. Before leaving the
operator's seat, always operate the work equipment
lock lever and parking brake lever to place it securely
at the LOCK position.
1. Stop the machine. For details, see “STOPPING MACHINE (3-79)“.
2. Set parking brake lever (1) to the LOCK position (L) and
apply the parking brake.
3. Push blade control lever (2) down to position (C) to lower

the blade on the ground.
3-94
OPERATION OPERATION
4. Set work equipment lock leve (3) in the LOCK position (L).
CHECK AFTER FINISHING WORK 3
BEFORE STOPPING ENGINE 3

Use the meters and caution lamps to check the engine coolant
temperature, engine oil pressure, fuel level, and Power train oil
temperature.
AFTER STOPPING ENGINE 3

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for
any leakage of oil or coolant. If any problems are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.
3-95
OPERATION OPERATION
LOCKING 3
To prevent vandalism, there are locks in the following places.
Places that can be locked with the starting switch key.
q Top cover at front of chassis (1)
q Right and left engine side covers (2)
q Battery inspection cover (3)
q Inspection cover for fuel tank drain valve(4)
q Cab door opener (5) (Machine equipped with cab)
q Fuel tank filler cap (6)
q Hydraulic tank filler cap (7)
q Power train filter inspection cover (8)
q Engine cooling water sub-tank inspection cover (9)
TIPS FOR LONGER UNDERCARRIAGE LIFE 3

Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient
operation, keep the following points in mind.
OPERATION METHOD 3
q Select the track shoe that best suits the type of soil to be encountered in service.
Please consult your Komatsu distributor when selecting track shoes.
q Do not allow shoe slipping to occur during operation.
If shoe slipping occurs, reduce load on the blade until slipping stops.
q Avoid sudden starts, acceleration or stops, unnecessary high speeds and sharp turns.
q Always operate machine in a straight line whenever possible. When making turns, be careful not to allow the
machine to stay to one side, so operation in both turning directions can be done properly. Make turns with the
largest possible radius.
q Prior to operation, clear boulders and obstacles to prevent machine from riding over them while operating.
q On a slope, operate the machine parallel to the inclination

of the slope. Do not operate across the slope. Also when
stopping the machine on a slope, the machine should face
the top of the slope.
q When ground inclines to the left or right during digging

operations, do not continue to dig with the incline. Move
the machine back to level ground and start to dig again.
3-96
OPERATION OPERATION
q Do not force the machine to carry out work that exceeds its
working capability. Such work includes cases where the
idler or sprocket come off the ground when the machine
meets obstacles that resist the power of the machine dur-
ing dozing or ripping operations.
INSPECTION AND ADJUSTMENT 3

q Adjust the track shoe tension to an adequate level.
The track shoe tension can be measured in terms of clear-

ance “a“ between the front idler and carrier rollers as
shown in the figure at right. While this clearance is nor-
mally 20 mm to 30 mm, increase the tension slightly on a
rocky terrain and decrease on the clayish ground.
An excessively loose track shoe can create an abnormal

vibration to the machine during the work or cause the
sprocket teeth to wear prematurely.
(For an inspection and maintenance method, see “CHECK

TRACK SHOE TENSION, ADJUST (4-27)“. Referring to
that section, carry out an inspection and adjustment of
track shoe tension.)
q Check idler rollers for oil leakage as well as for loose bolts
and nuts. If any trouble is detected, repair immediately.
q Check a clearance (B) between front idler guide plate (1)

and track frame (2). As clearance (B) becomes larger, it
can cause the front idler to sway sideways and cause the
track shoe to jump off rollers. (For an inspection and main-
tenance method, see “ADJUST IDLER CLEARANCE (4-
40)“.
INSPECTION AND REPAIR 3

Frequent inspection and prompt repair will reduce repair costs.
The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per-
form periodical inspection and contact the Komatsu distributor in your area when machine has approached repair-
able limits and reversing limits.
3-97
OPERATION OPERATION
MEASURING LINK PITCH
1. Insert a wooden block between track shoe and sprocket to

take up the slack in track shoes.
2. Measure the pitch length (L) of 4 links at a straight portion

at least 2 links from master pin (A). Divide this measure-
ment by four to obtain the link pitch.
q Basic link pitch (P): 203 mm
q Link pitch limit for turning: 206 mm
There is no link window on the master link.
REMARK
The measured value under decimal of link pitch is different
from the basic value depending upon the precision of measure
or the tolerance of product even if it isn't worn out.
Don't judge it's worn out too soon, do it with the trend of mea-
sured value after that.
MEASURING HEIGHT OF GROUSER
(D65EX,D65WX)
After taking up slack in track shoes, measure height at center

of shoe as shown below.
q Standard height (h): 65 mm
q Repair limits: 25 mm
3-98
OPERATION OPERATION
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER
1. Measure the height (dimension C) of the link tread as

shown in the diagram.
2. Stop machine at position where link tread, whose size C

has been measured completely, contacts roller tread. Then
measure size B.
3. Calculate outside diameter of tread (size A):
A = (B - C) x 2
q Standard size (A): 210 mm
q Repair limits: 172 mm
3-99
TRANSPORTATION OPERATION
TRANSPORTATION 3
When transporting the machine, observe all related laws and
regulations, and be careful to assure safety.
TRANSPORTATION MEANS 3
When transporting the machine, choose the optimum transportation method in reference to the weight and dimen-
sions shown in “SPECIFICATIONS (5-2)“. Note that machine specifications (weight and dimensions) vary depend-
ing on the kind of track shoes and blades.
REMOVING CAB 3
If it is necessary to remove the cab for transportation, there is danger that the seal may be damaged when remov-
ing or installing the cab, so please contact your Komatsu distributor.
When installing the cab, please contact your Komatsu distributor, too.
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT 3

If there is any pressure remaining in the tilt piping after the work equipment has been removed, it may be difficult to
remove the quick coupler of the tilt hose, so remove the work equipment as follows.
1. Lower the blade to the ground and set it horizontal to the

ground surface.
REMARK
If the blade is tiled, the tilt piping will be under internal pressure,
so set the blade horizontal to the ground.
2. Remove the quick coupler (1), then remove the work

equipment assembly.
3-100
OPERATION TRANSPORTATION
3. Remove right and left trunnions (2).
(D65PX,D65WX)
REMARK
If the machine model is D65PX and D65WX, remove right and
left trunnions (2).
If the machine model is D65EX, it is not necessary to remove
right and left trunnions (2), because the width including them
(A) is less than 3.0 m.
If the machine model is D65EX with a 3-m long semi U blade, it
is not necessary to remove the work equipment, because the
blade width is less than 3.0 m.
4. Tie the tilt hose with a band to prevent it from being dam-
aged.
PRECAUTIONS WHEN REMOVING ROPS 3

When removing ROPS for transporting the machine, do as follows:
NOTICE
ROPS is an important safety component. Be sure to
tighten mounting bolts (1) securely to the specified torque
when installing.
Tightening torque: 785 to 980 N·m (80 to 100 kgf·m)
1. Loosen bolts (1) and remove ROPS.
3-101
LOADING, UNLOADING WORK 3
WARNING
q Since loading and unloading of the machine is dangerous, be extremely careful.
q When loading or unloading the machine, operate it slowly with the engine speed low and the transmis-
sion in the 1st gear.
q Use ramps having sufficient width, length, thickness, and strength. Install them securely and set their
angle to 15° or less.
If the ramps are deflected appreciably, reinforce them with blocks.
q Perform the loading work of the machine on firm, level ground. Secure sufficient distance between the
shoulder of the road and the trailer.
q Remove mud from the undercarriage of the machine so that the machine will not slip sideways on the
ramps. In addition, remove water, snow, ice, grease, oil, etc. from the ramps.
q Never steer the machine on the ramps, since steering on the ramps can cause the machine to tip over.
If it is necessary to change the travel direction, return to the ground or to the bed of the trailer, then
change the travel direction.
q The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and
the machine is unbalanced and becomes dangerous. Accordingly, pass the border slowly.
When loading or unloading, always use ramps or a platform. Proceed as follows.
LOADING WORK
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely and put blocks (1) under
the tires to hold the trailer in position. Set gap (3) between
ramps (2) to match the distance between the left and right
tracks, and keep angle (4) to a maximum of 15°.
If ramps (2) bend appreciably under the weight of the

machine, put wooden block (5) under the ramps to support
them.
3. Start the engine.
In a cold weather, carry out an engine warming-up run, referring to the section, “STARTING IN COLD
WEATHER (3-74)“, in this manual.
3-102
4. Set parking brake lever to the FREE position (F).
5. Set the transmission in the 1st gear and run the engine at
low idle.
6. Set the travel direction toward the ramps and drive slowly.
7. The center of gravity of the machine shifts suddenly at the

border between the ramps and trailer, and the machine is
unbalanced and becomes dangerous. Accordingly, pass
the border slowly.
8. Stop the machine at the specified position on the trailer.
SECURING MACHINE
NOTICE
Be sure to lower the car radio antenna to the stow position (if the machine is equipped with a cab).
Load the machine onto a trailer as follows:
1. Lower the work equipment slowly.
(When transporting with work equipment installed)
2. Set the work equipment lock lever to the LOCK position (L)
securely.
3. Set the parking brake lever to the LOCK position (L)

securely.
4. Stop the engine, then remove the key from the starting
switch.
3-103
5. Fix the machine as explained below so that it will not move

during transportation.
In particular, fix the machine securely to prevent it from

slipping sideways.
6. Put blocks (1) in front and behind the track shoes of both
sides.
7. Set up chain or wire, following (A) or (B).
q A: Secure chain or wire around the track shoes.
q B: Secure chain or wire through the holes of track links.
8. Protect the wire from contacting directly with angular parts

of the machine, by inserting pads.
UNLOADING WORK
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely and put blocks (1) under
the tires to hold the trailer in position. Set gap (3) between
ramps (2) to match the distance between the left and right
tracks, and keep angle (4) to a maximum of 15°.
If ramps (2) bend appreciably under the weight of the

machine, put wooden block (5) under the ramps to support
them.
3. Remove the chains and wire ropes fastening the machine.
In a cold weather, carry out an engine warming-up run, referring to the section, “STARTING IN COLD
WEATHER (3-74)“, in this manual.
5. Set main work equipment lock lever to FREE position (F),

and raise the work equipment.
3-104
6. Set parking brake lever to the FREE position (F).
7. Set the transmission in the 1st gear and run the engine at
low idle.
8. Set the travel direction toward the ramps and drive slowly.
9. The center of gravity of the machine shifts suddenly at the

border between the ramps and trailer, and the machine is
unbalanced and becomes dangerous. Accordingly, pass
the border slowly.
10. Drive down the ramps slowly and carefully until the
machine leaves the ramps perfectly.
LIFTING MACHINE 3
WARNING
q The person using the crane to carry out lifting operations must be a qualified crane operator.
q Never carry out lifting operations if any person is on the machine being lifted.
q Always use a wire rope that has ample strength for the weight of the machine being lifted.
q Keep the machine horizontal when lifting it.
q When carrying out lifting operations, set the work equipment lock lever and parking brake lever to the
LOCK position to prevent the machine or work equipment from moving unexpectedly.
q Never enter the area under or around a raised machine.
q There is danger of the machine losing its balance.

Use the procedure below to set the machine in the proper posture and use the lifting equipment when
lifting the machine.
NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to attachments and options actually installed on the machine. For
the proper lifting procedures, contact your Komatsu distributor.
For details of the weight, see “SPECIFICATIONS (5-2)“.
3-105
PROCEDURE FOR LIFTING OPERATIONS
q Hang the front wire ropes to each cylinder support (1) on the right and left sides.
q Fit the wire ropes at the rear to both left and the right pivot shafts (2).
For machine equipped with ripper
q Fit the wire ropes at the center to both left and the right pivot shafts (2).
q Hang the rear wire rope to ripper beam (3).
When lifting the machine, stop it on a level place, then observe the following procedure.
3-106
1. Stop the engine and set the parking brake lever to the
LOCK position (L) securely.
2. Set the work equipment lock lever to the LOCK position (L)
securely.
3. Install wire ropes, slings, etc. matched to the weight of the

machine to the lifting points as shown in the above figure.
NOTICE
q Use protectors, etc. so that the wire ropes will not be
broken at sharp edges or narrow places.
q Use spreaders and bars having sufficient width so that

they will not touch the machine.
4. After setting the wire ropes, lift up the machine and stop at 100 to 200 mm above the ground, and check that
the wire ropes are not slack and the machine is level, then lift up slowly.
TRAVELING ON ROADS 3
q When traveling on paved roads, use flat shoes to protect their surface.
Even when travelling a short distance, always place boards to protect the road surface.
REMARK
Note that the asphalt road becomes soft in summer.
3-107
COLD WEATHER OPERATION OPERATION
COLD WEATHER OPERATION 3
PRECAUTIONS FOR LOW TEMPERATURE 3

If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol-
lows.
FUEL AND LUBRICANTS
Change to oil with low viscosity for all components. For details of the specified visicosity, see “RECOMMENDED
FUEL, COOLANT, AND LUBRICANT (4-12)“.
COOLANT
WARNING
q Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your
eyes or on your skin, wash it off with large amounts of fresh water and see a doctor at once.
q When changing the coolant or when handling coolant containing antifreeze that has been drained
when repairing the radiator, please contact your Komatsu distributor or request a specialist company
to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto
the ground surface.
q Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
q Use Komatsu Supercoolant wherever available, or use permanent type antifreeze coolant.
q Never use methanol, ethanol, or propanol-based antifreeze.
q Do not use any water leakage prevention agent, either alone, or in combination with antifreeze.
q Do not mix one brand of antifreeze with a different brand.
For details on the amount of antifreeze mixture and on when to change the coolant, see “CLEAN INSIDE OF
COOLING SYSTEM (4-24)“.
BATTERY
WARNING
q The battery generates flammable gas. Do not bring fire or sparks near the battery.
q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
q Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.
q Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
3-108
OPERATION COLD WEATHER OPERATION
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low,
the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against
cold temperature to ensure the machine can be started easily the next morning.
REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte Temperature
Charging
(°C)
Rate (%)
20 0 -10 -20
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
q As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine,
store the battery in a warm place, and install it again the next morning.
q If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after
the day's work to prevent diluted electrolyte in the battery from freezing during the night.
AFTER COMPLETION OF WORK 3

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
q Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to
prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
q Park the machine on hard, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to be moved the next morn-
ing.
q Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
q Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.
AFTER COLD WEATHER 3

When the season changes and the weather becomes warmer, do as follows.
q Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (4-12)“.
3-109
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE 3
BEFORE STORAGE 3
When keeping in long-term storage (more than one month), store as follows.
q Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select
level ground and cover the machine with a sheet.
q Completely fill the fuel tank. This prevents moisture from collecting.
q Lubricate and change the oil before storage.
q Apply a thin coat of grease to metal surface of the hydraulic piston rods and the idler adjusting rods.
q Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it sepa-
rately.
q Place all control levers in the neutral position, set the work equipment lock lever and parking brake lever in the
LOCK position, and set the fuel control dial to the low idling position.
q To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type anti-
freeze (density between 30% and 68%).
DURING STORAGE 3
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors
and windows to improve ventilation and prevent gas poisoning.
q During storage, operate and move the machine for a short distance once a month so that a new film of oil will
coat moving parts. At the same time, also charge the battery.
q When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
q If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month
to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In
addition, check the refrigerant level twice a year.
AFTER STORAGE 3
NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine after long-term storage, do as follows before using it.
q Wipe off the grease from the hydraulic cylinder rods.
q Add oil and grease at all lubrication points.
q When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and
after starting the engine. If there is water in the oil, change all the oil.
3-110
OPERATION TROUBLESHOOTING
TROUBLESHOOTING 3
AFTER RUNNING OUT OF FUEL 3

When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before
starting the engine.
PROCEDURE FOR BLEEDING AIR 3

1. Insert the key into the engine starting switch and turn the
key to ON position (B). Then the electric priming pump
begins to work.
2. After holding the key in ON position (B) for 30 seconds,

turn it back to OFF position (A) and hold it there for 10 sec-
onds.
3. Repeat Steps 1 and 2 four times.
4. Turn the engine starting switch key to START position (C)

to start up the engine.
5. If the engine does not start up even after the engine starting motor is kept running for 20 seconds, repeat the
procedures of Step 1 through Step 4.
3-111
TROUBLESHOOTING OPERATION
METHOD OF TOWING MACHINE 3
WARNING
Serious injury or death could result if a disabled machine
is towed incorrectly or if there is a mistake in the selection
or inspection of the wire rope.
If the engine does not start, put blocks under the track to
prevent the machine from moving, then release the brake.
If blocks are not use, there is danger that the machine may
move suddenly.
Always check that the wire rope used for towing has ample
strength for the weight of the machine being towed.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope
may break during the towing operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the tow-
ing machine and the machine being towed.
Operate the machine slowly and be careful not to apply
any sudden load to the wire rope.
NOTICE
The maximum towing capacity for this machine is 197,100
N (20,100 kgf).
Always carry out towing operations within the maximum
towing capacity.
For details of the method of towing, please contact your Komatsu distributor.
q If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic system,
the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the
brake circuit must be heightened to the specified level with a special device. Ask your Komatsu distributor.
q Moving a machine by towing is only used to move it to a place where it is possible to carry out inspection and
maintenance. It is not intended for moving the machine long distances. Do not use this method for towing the
machine for long distances.
q If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the
machine.
q Keep the angle of the towing line to the minimum. Operate the machine so that the angle does not become
greater than 30° from the straight line.
3-112
If the machine gets stuck in the mud or a heavy thing needs to

be towed, install a towing wire rope to the draw bar pin.
q Connect a wire rope to the part indicated with the arrow in

the diagram at right.
IF BATTERY IS DISCHARGED 3
WARNING
q It is dangerous to charge a battery when mounted on a
machine. Make sure that it is dismounted before
charging.
q When checking or handling the battery, stop the

engine and turn the starting switch key to the OFF
position.
q The battery generates hydrogen gas, so there is a haz-

ard of explosion. Do not bring lighted cigarettes near
the battery, or do anything that will cause sparks.
q Battery electrolyte is dilute sulfuric acid, and it will

attack your clothes and skin. If it gets on your clothes
or on your skin, immediately wash it off with a large
amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
q When handling batteries, always wear safety glasses

and rubber gloves.
q When removing the battery, first disconnect the cable

from the ground (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis,
there is danger that it will cause a spark, so be
extremely careful.
q If the terminals are loose, there is danger that the

defective contact may generate sparks that will cause
an explosion.
q When removing or installing the terminals, check

which is the positive (+) terminal and which is the neg-
ative (-) terminal.
3-113
REMOVE AND INSTALL BATTERY 3

1. Open the battery cover.
2. Before removing battery, remove the ground cable (normally connected to the negetive (-) terminal). If any tool
touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the
nuts of the terminal and remove the wires from the battery.
3. After installing the battery, fix it with the battery hold down.
Tightening torque: 1.47 to 1.96 N·m (0.15 to 0.2 kgf·m)
4. When installing the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 5.9 to 9.8 N·m (0.6 to 1.0 kgf·m)
PRECAUTIONS FOR BATTERY CHARGING 3

If the battery is charged improperly, it may explode. Accord-
ingly, charge it according to “IF BATTERY IS DISCHARGED
(3-113)“ and the instruction manual attached to the charger,
and observe the following items.
q Set the voltage of the charger to match the voltage of the

battery to be charged. If the correct voltage is not selected,
the charger may overheat and cause an explosion.
q Connect the positive (+) charger clip of the charger to the

positive (+) terminal of the battery, then connect the nega-
tive (-) charger clip of the charger to the negative (-) termi-
nal of the battery. Be sure to attach the clips securely.
q Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire
and explode.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may
cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electro-
lyte level to the UPPER LEVEL line.
3-114
STARTING ENGINE WITH BOOSTER CABLE 3

When starting the engine with a booster cable, do as follows:
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
q When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.
q When starting the engine with a booster cable, wear

safety glasses and rubber gloves.
q Be careful not to let the normal machine and problem

machine contact each other. This prevents sparks from
generating near the battery which could ignite the
hydrogen gas given off by the battery.
q Make sure that there is no mistake in the booster cable

connections. The final connection is to the engine
block of the problem machine, but sparks will be gen-
erated when this is done, so connect to a place as far
as possible from the battery.
q When disconnecting the booster cable, take care not

to bring the clips in contact with each other or with the
machine body.
NOTICE
q The starting system for this machine uses 24V. For the normal machine, also use a 24V battery.
q The size of the booster cable and clip should be suitable for the battery size.
q The battery of the normal machine must be the same capacity as that of the engine to be started.
q Check the cables and clips for damage or corrosion.
q Make sure that the cables and clips are firmly connected.
q Check that the work equipment lock levers and parking brake levers of both machine are in the LOCK
position.
q Check that each lever is in the NEUTRAL position.
3-115
CONNECTING THE BOOSTER CABLE
Keep the starting switch of the normal machine and problem machine in the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Connect the clip of booster cable (A) to the positive (+) ter-
minal of battery (C) on the problem machine.
2. Connect the clip at the other end of booster cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of booster cable (B) to the negative (-) ter-
minal of battery (D) on the normal machine.
4. Connect the clip at the other end of booster cable (B) to

engine block (E) on the problem machine.
STARTING ENGINE
WARNING
Always check that the work equipment lock lever is set to the LOCK position, regardless of whether the
machine is working normally or has failed. Check also that all the control levers are in the HOLD or NEU-
TRAL position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle speed.
3. Turn the starting switch of the problem machine to the START position and start the engine.
If the engine doesn't start at first, try again after 2 minutes or so.
DISCONNECTING THE BOOSTER CABLE
After the engine has started, disconnect booster cables in the reverse order in which they were connected.
1. Remove the clip of booster cable (B) from engine block (E)
on the problem machine.
2. Remove the clip of booster cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (C) on the problem machine.
3-116
OTHER TROUBLE 3
ELECTRICAL SYSTEM 3
q ( ): Always contact your Komatsu distributor when dealing with these items.
q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Main cause Remedy

•Defective wiring (•Check, repair loose terminals, dis-
Lamp does not glow brightly even
connections
when the engine runs at high speed
•Check fuses and diodes in
Lamp flickers while engine is run-
fuse box)
ning
Battery charge circut caution lamp •Defective°belt •Replace

dose not go out even when engine is •Defective alternator (•Replace)
running •Defective wiring (•Check, repair
Check fuse, diode in fuse box)
Abnormal noise is generated from
•Defective alternator (•Replace)
alternator
Starting motor does not turn when •Defective wiring (•Check, repair)
starting switch is turned to ON •Insufficient battery charge •Charge
Pinion of starting motor keeps going
•Insufficient battery charge •Charge
in and out
Starting motor turns engine slug- •Insufficient battery charge •Charge
gishly •Defective starting motor (•Replace)
Starting motor disengages before •Defective wiring (•Check, repair)
engine starts •Insufficient battery charge •Charge
Engine preheating pilot lamp does
•Defective wiring (•Check, repair)
not light up
•Defective monitor (•Replace)
(When the temperature of the
•Disconnection in glow plug (•Replace)
engine coolant exceed 20°C, this
condition is normal)
•Blown fuse (•Check, repair)
Air conditioner operation is defective
•Insufficient battery charge •Charge
•Defective air conditioner switch (•Replace air conditioner switch)
•Defective blower switch (•Replace blower switch)
•Defective compressor (•Replace)
3-117
MONITOR PANEL 3
When an error code appears on the display panel B (multi-

information), take appropriate remedies based upon the table
below.
(1): Display panel B
(2): Warning lamp (red)
REMARK
If different kinds of failures occur at the same time, their failure
codes are arranged in the order of seriousness in the display.
The order of seriousness in this case is E04, E03, E02 and
E01, starting from the most serious one.
Action Warning Alarm

Display panel B Remedy
code lamp buzzer
Failure in part of function, stops. When con-
Top line: Displays E01 tinuing operations, be extremely careful of
E01 - -
Bottom line: Displays service meter location of failure. After completing opera-
tions, contact Komatsu distributor for repairs
Serious failure in part of function, stops.
When continuing operations, be extremely
Top line: Displays E02
E02 Flashes Sounds careful of location of failure. After completing
Bottom line: Displays service meter
operations, contact Komatsu distributor for
repairs
Bottom line: After moving to safe place, stop machine
E03 Displays telephone number Flashes Sounds immediately. Contact Komatsu distributor for
(If no telephone number is set, dis- repairs
plays 0)
Bottom line: Displays telephone
Stop machine immediately.
E04 number Flashes Sounds
Contact Komatsu distributor for repairs
(If no telephone number is set, dis-
plays 0)
Note: If a problem display appears on display panel B, check the fault code. For details, see “METHOD OF
USING FAULT CODE DISPLAY MODE (3-26)“.
When contacting your Komatsu distributor, please give the fault code also.
3-118
CHASSIS 3
Problem Main causes Remedy

•Improper tightening of oil pipe, •Check, repair
pipe joint, air leaking in or oil
leaking out because of
damage
Oil pressure in torque converter fails •Wear, scuffing of gear pump (•Check, replace)
to rise •Insufficient oil in power train •Add oil to the specified level.
case For details, see CHECK
BEFORE STARTING
•Clogged oil filter element •Clean. For details, see EVERY
strainer in power train case 500 HOURS SERVICE
•Clogged radiator •Clean radiator core
•Engine coolant temperature is •See ENGINE related parts
high
•Clogged oil cooler (•Clean or repalce)
Torque converter is overheats •Oil pressure too low •Go to “Oil pressure in torque
converter fails to rise“
•Lack of flow of lubricant caused (•Replace gear pump)
by wear of power train gear
pump
Torque converter oil temperature •Defective oil temperature gauge (•Replace oil temperature gauge)
gauge does not work •Defective contact in wiring connec- (•Check, repair)
tion
•Lack of engine horsepower •See ENGINE related parts
Lacks drawbar pull (machine does
•Oil pressure in torque converter is •Go to “ Oil pressure in torque con-
not pick up speed)
too low verter fails to rise“
•Add oil to specified level. For
•Insufficient oil in power train case
details, see CHECK BEFORE
STARTING
•Transmission oil pressure does not
•Go to oil pressure in torque con-
Machine will not move when joystick rise
verter fails to rise
is placed in FORWARD •Defective Brake
(•Adjust linkage)
•Defective lever wiring
(•Check, repair)
•Parking brake lever is in LOCK
•Set to FREE position
position
•Defective lever wiring (•Check, repair)

Does not steer even when steering
•Abnormal HSS pump (•Check, replace)
is operated
•Abnormal HSS motor (•Check, replace)
Machine doesn't stop when brake •Defective brake adjustment (•Adjust linkage)
pedal are depressed (•Check brake pressure)
•Track is too loose •Adjust track tension. For details,
Track comes off
see WHEN REQUIRED
•Track is too loose or too tight •Adjust track tension. For details,
Sprocket develops abnormal wear
see WHEN REQUIRED
•Initial improper adjustment of HSS (•Adjust)
Machine does not travel in straight
controller
line
•Defective HSS pump (•Replace)
3-119

•Lack of hydraulic oil •Add oil to specified level. For
details, see EVERY 250 HOURS
Blade rises too slowly or does not
SERVICE
rise at all
•Defective hydraulic pump •Check
(or blade tilts too slowly)
•Work equipment lock lever is in •Set to FREE position
LOCK position
3-120
ENGINE 3

•Add oil to specified level, see
•Engine oil pan oil level is low (suck-
CHECK BEFORE STARTING
ing in air)
•Replace cartridge, see EVERY
Engine oil pressure monitor flashes •Clogged oil filter cartridge
500 HOURS SERVICE
when engine speed is raised after
(•Check, repair)
completion of warm-up •Defective tightening of oil pipe joint,
oil leakage from damaged part
•Defective monitor panel
(•Replace)
Steam is emitted from top part of •Coolant level low, water leakage •Add coolant, repair, see
radiator (pressure valve) CHECK BEFORE STARTING
•Dirt or scale accumulated in cooling •Change coolant, clean
system inside of cooling system, see
WHEN REQUIRED
•Clogged radiator fins or damaged •Clean or repair, see WHEN
Engine water temperature monitor
fins REQUIRED
remains alight altitude operation)
•Defective thermostat (•Replace thermostat)
•Loose radiator filler cap (high alti- •Tighten cap or replace packing
tude operation)
•Defective monitor panel (•Replace)
•Lack of fuel
•Add fuel, see CHECK BEFORE
STARTING
•Air in fuel system
•Repair place where air is sucked in
Engine does not start when starting (•Replace pump or nozzle)
•No fuel in fuel filter
motor is turned •See ELECTRICAL SYSTEM
•Starting motor cranks engine slug-
gishly
•See ELECTRICAL SYSTEM
•Defective electric priming pump
(•Adjust valve clearance)
•Defective valve compression
•Too much oil in oil pan •Refill with engine oil up to the spec-
ified level, referring to CHECK
BEFORE STARTING.
Exhaust gas is white or blue
•Defective cooling water tempera- •Replace the sensor or repair the
ture sensor wiring harness.
•Improper fuel •Change to specified fuel
•Clogged air cleaner element •Clean or replace, see WHEN
REQUIRED
Exhaust gas occasionally turns
•Defective nozzle (•Replace nozzle)
black
•Defective compression (•Adjust valve clearance)
•Defective turbocharger (•Clean or replace, turbocharger)
Combustion noise occasionally •Defective nozzle (•Replace nozzle)
makes breathing sound •Lack of fuel (in Air) •Add fuel
•Low grade fuel being used •Change to specified fuel
•Overheating •See item “Indicator of water
Abnormal noise generated (combus- temperature gauge is in red
tion or mechanical) range on right side of gauge“.
•Damage inside muffler (•Replace muffler)
•Excessive valve clearance (•Adjust valve clearance)
3-121

Monitor displays error code
Alarm buzzer sounds
Engine horsepower lowered sud- Please contact your Komatsu distributor
denly
(Engine is running in duration mode)
3-122
3-123
3-124
MAINTENANCE
14
WARNING
Please read and make sure that you understand the SAFETY
GUIDE TO MAINTENANCE MAINTENANCE
GUIDE TO MAINTENANCE 4
Do not perform any inspection and maintenance operation that is not found in this manual.
CHECK SERVICE METER:
Check the service meter reading every day to see if the time has come for any necessary maintenance to be per-
formed.
KOMATSU GENUINE REPLACEMENT PARTS:
Use Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE OILS:
Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.
ALWAYS USE CLEAN WASHER FLUID:
Use automobile window washer fluid, and be careful not to let any dirt get into it.
CLEAN OIL AND GREASE:
Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
CHECKING FOREIGN MATERIALS IN DRAINED OIL:
After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out
suitable action.
FUEL STRAINER:
If your machine is equipped with a fuel strainer, do not remove it while fueling.
WELDING INSTRUCTIONS:
q Turn off the engine starting switch.
q Do not apply more than 200 V continuously.
q Connect grounding cable within 1 m of the area to be welded. If grounding cable is connected near instru-
ments, connectors, etc., the instruments may malfunction.
q If a seal or bearing happens to come between the part being welded and grounding point, change the ground-
ing point to avoid such parts.
q Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
DO NOT DROP THINGS INSIDE MACHINE:
q When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and
will lead to failure. If you drop anything inside the machine, always remove it immediately.
q Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
MAINTENANCE GUIDE TO MAINTENANCE
DUSTY WORKSITES:
When working at dusty worksites, do as follows:
q Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged.
q Clean the radiator core frequently to avoid clogging.
q Clean and replace the fuel filter frequently.
q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
q When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from get-
ting into the oil.
AVOID MIXING OILS:
If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or
grade of oil. Never mix different brand or grade of oil.
PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER:
q Open the engine side cover all the way and ensure that it is
locked open before letting go.
q When standing on the track to open the engine side cover,

bend at the knees and open the cover in a standing posi-
tion to avoid back strain.
q Before opening the cab door, always close the engine side
cover.
If the lock for the engine side cover is not released, it will
not close. If any attempt is made to close it without releas-
ing the lock, the gas damper may break.
When closing the cover, push the orange button in the cen-
ter of the gas damper (1) to release the lock, then close the
cover.
LOCKING THE INSPECTION COVER:
Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly blow shut by the wind and cause
injury to the worker.
HYDRAULIC SYSTEM-AIR BLEEDING:
After repairing or replacing hydraulic equipment or after removing the hydraulic piping, it is necessary to bleed the
air from the circuit. For details, see “PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM (4-42)“.
4-3
GUIDE TO MAINTENANCE MAINTENANCE
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES:
q When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
q When installing the hoses, do not twist them or bend them sharply. If they are installed so, their service life will
be shortened extremely and they may be damaged.
CHECKS AFTER INSPECTION AND MAINTENANCE WORK:
If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do the following:
q Checks after operation (with engine stopped)
q Have any inspection and maintenance points been forgotten?
q Have all inspection and maintenance items been performed correctly?
q Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
q Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
q Checks when engine is running
q For the checks when the engine is running, see “TWO WORKERS FOR INSPECTION AND MAINTE-
NANCE WHEN ENGINE IS RUNNING (2-25)“ in the SAFETY section, and take care of safety sufficiently.
q Check that the inspected and maintained parts work normally.
q Raise the engine speed and check for fuel leakage and oil leakage.
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE:
Select the fuel and lubricants to match the ambient temperature.
For details, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (4-12)“.
4-4
MAINTENANCE OUTLINE OF SERVICE
OUTLINE OF SERVICE 4
q Always use Komatsu genuine parts for replacement parts, grease or oil.
q When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all
the old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem
if the small amount of oil remaining in the piping mixes with the new oil.)
q Unless otherwise specified, when the machine is shipped from the factory, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40DH (Komatsu genuine parts)
Power train case
Final drive case
Power train oil TO30 (Komatsu genuine parts)
Damper case
Idler (each)
Hydraulic system Power train oil TO10 (Komatsu genuine parts)
Radiator Supercoolant AF-NAC (Density: 30% or above) (Komatsu genuine parts)
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4
OIL 4
q Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in
the Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil at the specified inter-
val.
q Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
q Never mix oils of different grades or brands.
q Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
q If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
q When changing the oil, always replace the related filters at the same time.
q We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
q When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the
oil.
4-5
OUTLINE OF SERVICE MAINTENANCE
FUEL 4
q To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank after completing the day's work.
q The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
q Be extremely careful not to let impurities get in when storing or adding fuel.
q Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperatures below -
15°C), so it is necessary to use the fuel that is suitable for the temperature.
q Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water
from the fuel tank.
q If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
q If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
Always use diesel fuel. Never use any other fuel.
The engine on this machine uses electronic control and high-pressure fuel injection equipment to enable
it to provide good fuel consumption and good exhaust gas characteristics. For this reason, high-preci-
sion parts and lubricating ability are demanded. Using low-viscosity fuel with poor lubricating ability will
cause a marked reduction in the durability of the engine.
COOLANT AND WATER FOR DILUTION 4

q The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000
hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
q When diluting the antifreeze coolant, use distilled water or tap water (soft water).
Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium,
magnesium, etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is depos-
ited inside the engine or radiator, it is extremely difficult to remove. It also causes overheating due to poor heat
exchange, so when you dilute the coolant, we recommend that you use water with an overall hardness of less
than 100 PPM.
q When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
q Antifreeze coolant is flammable, so be sure to keep it away from flame.
q The ratio of Supercoolant (AF-NAC) to water differs according to the ambient temperature.
For details of the ratio when mixing, see “CLEAN INSIDE OF COOLING SYSTEM (4-24)“.
Supercoolant (AF-NAC) may be supplied already mixed. In such cases, never dilute with water.
q If the engine overheats, wait for the engine to cool before adding coolant.
q If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air
entering the coolant.
4-6
GREASE 4
q Grease is used to prevent seizure and noises at the joints.
q This construction equipment is used under heavy-duty conditions. Always use the recommended grease and
follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance
Manual.
q The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not
need grease.
If any part becomes stiff or generates noise after being used for a long time, grease it.
q Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) 4

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other problems.
We strongly recommend you to use this service. The oil analysis is carried out at actual cost, so the cost is low,
and the results of the analysis are reported together with recommendations which will reduce repair costs and
machine downtime.
KOWA ANALYSIS ITEMS
q Measurement of density of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to

measure the density of iron, copper, and other metal wear
particles in the oil.
q Measurement of quantity of particles
This uses a particle quantifier index measurement machine

to measure the quantity of iron particles of 5µ or more,
enabling early detection of failures.
q Others
Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of
fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.
4-7
OUTLINE OF SERVICE MAINTENANCE
OIL SAMPLING
q Sampling interval
250 hours: Engine
500 hours: Other components
q Precautions when sampling
q Make sure that the oil is well mixed before sampling.
q Perform sampling at regular fixed intervals.
q Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
STORING OIL AND FUEL 4

q Keep indoors to prevent any water, dirt, or other impurities from getting in.
q When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the
side to prevent moisture from being sucked in.
If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
q To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).
FILTERS 4
q Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
q Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
q When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are
found, contact your Komatsu distributor.
q Do not open packs of spare filters until just before they are to be used.
q Always use Komatsu genuine filters.
RELATING TO ELECTRIC SYSTEM 4

q It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged.
This will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of
the operator's cab with water. When washing the machine, be careful not to let water get into the electrical
components.
q Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt
and checking battery fluid level.
q Never install any electric components other than those specified by Komatsu.
q External electro-magnetic interference may cause malfunction of the control system controller, before install-
ing a radio receiver or other wireless equipment, contact your Komatsu distributor.
4-8
q Be careful to keep the electric system free of water when washing the machine or when it rains.
q When working at the seashore, carefully clean the electric system to prevent corrosion.
q When installing electrical equipment, connect it to the special power source connector.
Do not connect the optional power source to the fuse, starting switch, or battery relay.
HANDLING HYDRAULIC SYSTEM 4

q During operations and after completion of operations, the hydraulic equipment is at a high temperature. Dur-
ing operations, it is also under high pressure, so when carrying out inspection and maintenance of hydraulic
related equipment, be careful of the following points.
q Stop the machine on flat ground, lower the work equipment completely to the ground, and carry out the
operation so that there is no pressure on the cylinder circuits.
q Always stop the engine.
q Immediately after stopping operations, the hydraulic oil and lubricating oil is at high temperature and high
pressure, so wait for the oil temperature to go down before starting maintenance.
Even after the temperature has gone down, some parts may still be under internal pressure, so when loos-
ening plugs, bolts, or hose connections, do not stand directly in front of the parts, and loosen slowly to
release the internal pressure before removing.
q When carrying out inspection and maintenance of the hydraulic circuit, always release the air in the
hydraulic tank to remove the internal pressure.
q Inspection and maintenance include checking the hydraulic system for oil level, replacement of filter elements
and replacement of hydraulic oil.
q If high-pressure hoses have been removed, check that there is no damage to the O-rings. If any damage is
found, replace the O-ring.
q It is necessary to bleed the air from the circuits when the hydraulic filter element or strainer have been
replaced or washed, or when hydraulic equipment has been repaired or replaced, or when the hydraulic piping
has been removed.
q The accumulator is charged with high-pressure nitrogen gas, and it is extremely dangerous if it is handled
incorrectly. For details of the method of handling, see “CHECKING CHARGE PRESSURE OF NITROGEN
GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) (4-66)“.
4-9
WEAR PARTS LIST MAINTENANCE
WEAR PARTS LIST 4

Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of
the machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.
WEAR PARTS LIST 4

The parts in parentheses are to be replaced at the same time.
Replacement fre-
Item Part No. Part Name Weight (kg) Q'ty
quency
Every 500 hours
Engine oil filter 6742-01-4540 Cartridge - 1
service (**)
14X-49-32750 Element - 1
Power train filter
(07000-72110) (O-ring) - (1) Every 500
Cartridge hours service
Fuel pre-filter 600-319-3610 - 1
(with O-ring for clear ball)
Cartridge
Fuel main filter 6754-71-6130 - 1 Every 1000
(with cap)
hours service
Corrosion resistor 600-411-1191 Cartridge - 1
14X-60-31150 Element - 1
Hydraulic oil filter
(07000-15195) (O-ring) - (1) Every 2000
Hydraulic tank hours service
20Y-60-21470 Element - 1
breather element
Air cleaner 600-185-5100 Element Ass'y - 1 -
Air Fresh filter 14X-911-7750 Filter - 2
-
conditioner Recirc filter 20Y-979-6261 Filter - 2
14X-71-11310 Cutting edge 38.4 2
14X-71-11330 End bit (left) 14.2 1
D65EX
14X-71-11340 End bit (right) 14.2 1 -
Tiltdozer
(02090-11270) (Bolt) - (28)
(02290-11219) (Nut) - (28)
14Y-71-11210 Cutting edge 45.5 2
D65PX 13.6
14Y-71-11330 End bit (left) 1
Tiltdozer 13.6
14Y-71-11340 End bit (right) 1 -
Tilt pitch
(02090-11270) (Bolt) - (32)
dozer
(02290-11219) (Nut) - (32)
144-70-11131 Cutting edge 45.5 2
Blade
14X-71-11330 End bit (left) 14.2 1
D65EX 14.2
14X-71-11340 End bit (right) 1 -
Angle dozer
(02090-11270) (Bolt) - (32)
(02290-11219) (Nut) - (32)
130-70-51130 Cutting edge (center) 39.0 1
130-920-2180 Cutting edge (side) 34.0 2
13F-Z27-1581 End bit (left) 10.8 1
D65PX 10.8
13F-Z27-1571 End bit (right) 1 -
Angle dozer
(02090-11270) (Bolt) - (31)
(02091-11210) (Bolt) - (4)
(02290-11219) (Nut) - (35)
4-10
MAINTENANCE WEAR PARTS LIST
Replacement
Item Part No. Part Name Weight (kg) Q'ty
frequency
130-70-41130 Cutting edge (right) 37.5 1
130-920-2180 Cutting edge (left) 34.0 1
(02090-11270) (Bolt) - (17)
D65EX
(02290-11219) (Nut) - (17)
Semi-U blade -
175-71-22272 End bit (left) 39.0 1
(tilt dozer)
175-71-22282 End bit (right) 39.0 1
(02090-11495) (Bolt) - (14)
(02290-11422) (Nut) - (14)
14X-952-1270 Cutting edge 29.8 2
(02090-11270) (Bolt) - (14)
D65EX
(02290-11219) (Nut) - (14)
Semi-U blade
Blade 150-70-21356 End bit (left) 26.2 1 -
(3m)
150-70-21346 End bit (right) 26.2 1
(tilt dozer)
(02090-11280) (Bolt) - (12)
(02290-11219) (Nut) - (12)
14X-952-1450 Cutting edge 32.0 2
(02090-11270) (Bolt) - (18)
(02290-11219) (Nut) - (18)
D65WX
175-71-22272 End bit (left) 39.0 1
Semi-U blade
39.0
-
175-71-22282 End bit (right) 1
(tilt dozer)
(02090-11495) (Bolt) - (14)
(02290-11422) (Nut) - (14)
(01643-22245) (Washer) - (14)
NOTICE
When handling parts that weigh more than 25 kg, remember that they are heavy objects, and take the nec-
essary care.
q (**) For details about engine oil interval, refer to section, RECOMMENDED FUEL, COOLANT, AND LUBRI-
CANT (4-12)
4-11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4

q Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment
and components.
In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the
instructions in this Operation and Maintenance Manual.
q Failure to follow these recommendations may result in shortened life or excess wear of the engine, power
train, cooling system, and/or other components.
q Commercially available lubricant additives may be good for the machine, but they may also cause harm.
Komatsu does not recommend any commercially available lubricant additive.
q Use the oil recommended according to the ambient temperature in the chart below.
q Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity
means the amount of oil needed to refill the system during inspection and maintenance.
q When starting the engine in ambient temperatures below 0°C, do not use EO30DH, even if the daytime tem-
perature rises to 10°C. Always use multigrade oil such as the recommended EO10W30DH or EO15W40DH.
q If the machine is operated at a temperature below -20°C, a separate device is needed, so consult your
Komatsu distributor.
q When the fuel sulfur content is less than 0.5%, change the engine oil according to the period inspection table
given in this Operation and Maintenance Manual.
q If the fuel sulfur content is more than 0.5%, change the oil according to the following table.
NOTE: Only use Komatsu genuine engine oil.
Sulphur content (%) Oil change interval

Less than 0.5 500 hours
0.5 ~ 1.0 250 hours
Above 1.0 Consult Komatsu Distributor
* If using these fuels, serious troubles may occur because of early deterioration of engine oil or early wear of
engine internal parts. If using them by necessity for local situations, be sure to inform customers about the follow-
ing.
1) Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil based
on the result.
2) Always be aware that oil change interval is extremely shorter than standard.
3) Be sure to carry out periodic engine inspection by distributor's expert since change interval of periodic replace-
ment parts and overhaul interval are also shorter.
For details refer Note 1 at the end of this chaper.
4-12
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT

TEMPERATURE 4
AMBIENT
TEMPERATURE Recommended Komatsu Genuine
Reservoir Fluid type
Fluids
Min Max
SAE0W30EOS and HTHS Over 3.5cP.
-30°C 30°C (Note.1)
Komatsu EOS0W30
SAE5W40EOS and HTHS Over 3.5cP.
-25°C 40°C (Note.1)
Komatsu EOS5W40
Engine oil pan Engine oil
SAE10W30DH
-20°C 40°C
Komatsu EO10W30DH
SAE15W40DH
-15°C 50°C
Komatsu EO15W40DH
SAE30DH
0°C 40°C
Komatsu EO30DH
Damper case Power train oil
-30°C 50°C Komatsu TO30
Idler (each) (Note. 2)
-30 °C 10°C Komatsu TO10
Power train case (each) Power train oil
0 °C 50°C Komatsu TO30
Final drive case (each) Power train oil -30°C 40°C Komatsu TO30
Power train oil -20° C 40° C Komatsu TO10
Hydraulic oil -20° C 45° C Komatsu HO46-HM
Hydraulic system
-20° C 50° C Komatsu EO10W30DH
Engine oil
-15° C 50° C Komatsu EO15W40DH
Hyper grease
-20° C 50° C Komatsu G2-TE
Grease fitting (Note. 3)
Lithium EP grease -20° C 50° C Komatsu G2-LI
Supercoolant
Cooling sytem -30°C 50°C AF-NAC (Note. 4)
AF-NAC
0° C 50° C ASTM No. 2-D
Fuel tank Diesel fuel
-30° C 20° C ASTM No. 1-D
q SAE: Society of Automotive Engineers
q ASTM: American Society of Testing and Material
4-13
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
Final drive Cooling

Power
Engine Damper Idler Hydraulic case (each) Fuel system
train
oil pan case (each) system tank (including
case EX PX,WX sub-tank)
Specified
Liters 33 1.3 0.15 95 68 24 27 415 37
capacity
Refill
Liters 28 1.3 0.15 55 48 24 27 - -
capacity
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection device
to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high
precision for the parts and good lubrication.
If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability.
Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS ( High-Temperature High-Shear Vis-
cosity 150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable
oils. If these oils are not available, follow the instruction “RECOMMENDED BRANDS, RECOMMENDED QUAL-
ITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL (4-15)“ at the end of this chapter.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)
1) Coolant has the important function of anticorrosion as well as antifreeze.
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
2) For details of the ratio when diluting super coolant with water, see “CLEAN INSIDE OF COOLING SYSTEM (4-
24)“.
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant
(AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C, (never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
4-14
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS

OTHER THAN KOMATSU GENUINE OIL 4
When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifica-
tions, refer to the Komatsu web page or consult your Komatsu distributor.
4-15
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUES FOR BOLTS AND

NUTS 4
TORQUE LIST 4
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.
Thread diam- Tightening torque

Width across
eter of bolt Target value Service limit
flats (b)(mm)
(a)(mm) N·m kgf·m N·m kgf·m
6 10 13.2 1.35 11.8-14.7 1.2-1.5
8 13 31 3.2 27-34 2.8-3.5
10 17 66 6.7 59-74 6.0-7.5
12 19 113 11.5 98-123 10.0-12.5
14 22 172 17.5 153-190 15.5-19.5
16 24 260 26.5 235-285 23.5-29.5
18 27 360 37 320-400 33.0-41.0
20 30 510 52.3 455-565 46.5-58.0
22 32 688 70.3 610-765 62.5-78.0
24 36 883 90 785-980 80.0-100.0
27 41 1295 132.5 1150-1440 118.0-147.0
30 46 1720 175.0 1520-1910 155.0-195.0
33 50 2210 225.0 1960-2450 200.0-250.0
36 55 2750 280.0 2450-3040 250.0-310.0
39 60 3280 335.0 2890-3630 295.0-370.0
Apply the following table for Hydraulic Hose.
Nominal-
Width Tightening torque (N·m (kgf·m))
across
No. of
flats (b) Target valve Parmissible range
threads (a)
mm
9/16 -18UNF 19 44 (4.5) 34 - 54 (3.5 - 5.5)
11/16 -16UN 22 74 (7.5) 54 - 93 (5.5 - 9.5)
13/16 -16UN 27 103 (10.5) 84 - 132 (8.5 - 13.5)
1 -14UNS 32 157 (16.0) 128 - 186 (13.0 - 19.0)
1·3/16 -12UN 36 216 (22.0) 177 - 245 (18.0 - 25.0)
4-16
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out
periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next
page must also be replaced at the specified interval. These parts are particularly closely connected to safety and
fire prevention, so please contact your Komatsu distributor to have them replaced.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is impor-
tant to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the peri-
odic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.
SAFETY CRITICAL PARTS 4
NO. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (fuel tank - fuel strainer) 1
2 Fuel hose (fuel strainer to fuel pre-filter) 1
3 Fuel hose (fuel pre-filter to engine inlet) 1
4 Fuel return hose (engine outlet to fuel tank) 1
5 Hose (power train strainer - power train pump) 1
6 Hose (power train pump - power train filter) 1
7 Hose (power train filter - transmission case) 1
8 Hose (transmission case - steering case) 1
9 Hose (power train lubrication pump - steering case) 1
10 Hose (Scavenging pump - Steering case) 1 Every 2 years or
11 Hose (torque converter case - mission oil cooler) 1 4000 hours, which-
12 Hose (mission oil cooler - transmission case) 1 ever comes sooner
13 Brake pressure detection hose 1
14 Torque converter inlet post pressure detection hose 1
15 Torque converter outlet post pressure detection hose 1
16 Main relief valve pressure detection hose 1
17 Hose (HSS pump - main control valve) 2
18 Hose (HSS pump - central drain block) 1
19 Hose (self-reducing pressure valve - hydraulic tank) 1
20 Hose (main valve - HSS motor) 2
21 Hose (main valve - hydraulic tank) 1
4-17
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE
NO. Safety critical parts for periodic replacement Q'ty Replacement interval
22 Hose (main valve - central drain block) 1
23 Hose (main control valve - blade tilt relay block) 2
24 Hose (blade tilt relay block - Tilt cylinder) 8
25 Hose (main valve - blade tilt relay tube) 2
26 Hose (Radiator guard upper part - Lift cylinder) 4
27 Hose (self-reducing pressure valve - fan pump) 1
28 Hose (hydraulic tank - fan pump) 1
29 Hose (self-reducing pressure valve - fan motor) 1
30 Hose (fan motor - hydraulic oil cooler) 1
31 Hose (hydraulic tank - fan motor) 1
32 Hose ( hydraulic oil cooler - hydraulic tank) 1 Every 2 years or
33 Hose (central drain block - HSS motor) 1 4000 hours, which-
34 Hose (PPC valve - main valve) 4 ever comes sooner
35 Hose (central PPC block - main valve) 2
36 Hose (fan pump - central PPC block) 1
37 Hose (PPC lock valve - central PPC block) 1
38 Hose (self-reducing pressure valve - central PPC block) 1
39 Hose (PPC valve - PPC lock valve) 1
40 Hose (PPC valve - central drain block) 1
41 Hose (central drain block - hydraulic tank) 1
42 Hose (HSS delivery hose - pressure detection block) 1
43 Hose (HSS pump - pressure detection block) 1
44 Accumulator (for operating circuit) 1
45 High-pressure tube clamp 1S
Every 8000 hours
46 Fuel spray prevention cap 1S
47 Seat belt (If equipped) 1 Every 3 years
4-18
MAINTENANCE MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART 4
MAINTENANCE SCHEDULE CHART 4
WHEN REQUIRED 4
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT .......................................................................... 4-214
CLEAN INSIDE OF COOLING SYSTEM.......................................................................................................... 4-244
CHECK TRACK SHOE TENSION, ADJUST .................................................................................................... 4-274
CHECK AND TIGHTEN TRACK SHOE BOLTS ............................................................................................... 4-294
REVERSE AND REPLACE END BITS AND CUTTING EDGES...................................................................... 4-304
CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND
AFTER-COOLER .............................................................................................................................................. 4-324
CHECK, ADJUST AIR CONDITIONER ............................................................................................................ 4-354
GREASE DOOR HINGE ................................................................................................................................... 4-364
CHECK DOOR LOCK STRIKER ...................................................................................................................... 4-374
REPLACE DOOR DAMPER ............................................................................................................................. 4-374
CHECK DOOR LATCH ..................................................................................................................................... 4-374
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ............................................................................... 4-384
REPLACE WIPER BLADE................................................................................................................................ 4-394
CHECK IDLER OIL LEVEL, ADD OIL............................................................................................................... 4-404
ADJUST IDLER CLEARANCE.......................................................................................................................... 4-404
LUBRICATING UNIVERSAL JOINT ................................................................................................................. 4-414
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM ...................................................................... 4-424
EVERY 50 HOURS SERVICE 4

DRAIN WATER, SEDIMENT FROM FUEL TANK ............................................................................................ 4-434

LUBRICATING .................................................................................................................................................. 4-444
GREASE EQUALIZER BAR SIDE PIN ............................................................................................................. 4-454
GREASE EQUALIZER BAR CENTER PIN....................................................................................................... 4-464
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................... 4-464
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ..................................................................................... 4-474
CHECK LEVEL OF BATTERY ELECTROLYTE............................................................................................... 4-484
CHECK, CLEAN ADDITIONAL FUEL STRAINER............................................................................................ 4-494
CHECK BRAKE PERFORMANCE ................................................................................................................... 4-504
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)............................................................. 4-514

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ..................................... 4-524
REPLACE POWER TRAIN OIL FILTER ELEMENT......................................................................................... 4-544
REPLACE FUEL PRE-FILTER CARTRIDGE ................................................................................................... 4-544

REPLACE FUEL MAIN FILTER CARTRIDGE.................................................................................................. 4-574
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING
PUMP STRAINER) ........................................................................................................................................... 4-604
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL .......................................................................................... 4-624
4-19
MAINTENANCE SCHEDULE CHART MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................. 4-634

CLEAN BREATHER.......................................................................................................................................... 4-634
REPLACE CORROSION RESISTOR CARTRIDGE......................................................................................... 4-644
CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................................. 4-644
INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS.................................... 4-644

CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT ...................................................... 4-654
REPLACE HYDRAULIC TANK BREATHER ELEMENT .................................................................................. 4-664
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) . 4-664
CHANGE OIL IN DAMPER CASE .................................................................................................................... 4-694
CHECK VIBRATION DAMPER ......................................................................................................................... 4-704
CHECK ENGINE VALVE CLEARANCE, ADJUST ........................................................................................... 4-704

REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT )............................................................................... 4-714
CHECK WATER PUMP .................................................................................................................................... 4-714
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER........................ 4-724
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................... 4-734

REPLACE HIGH-PRESSURE PIPING CLAMP ................................................................................................ 4-744
REPLACE FUEL SPRAY PREVENTION CAP ................................................................................................. 4-744
4-20
MAINTENANCE SERVICE PROCEDURE
SERVICE PROCEDURE 4
WHEN REQUIRED 4
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4
WARNING
q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the
engine and damage it. Always stop the engine before carrying out these operations.
q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use protective glasses, dust mask, and other protective equipment.
CHECKING
If the yellow piston at the display portion of dust indicator (1)

becomes red (7.5 kPa), clean the outer element.
NOTICE
Do not clean the filter element until after a yellow piston in
the dust indicator display has come in the red area (7.5
kPa).
If the filter element is cleaned frequently before the yellow
piston in the dust indicator display comes in the red area
(7.5 kPa), the air cleaner cannot exert its inherent cleaning
capability, reducing its cleaning effect.
In addition, dust sticking to the element falls into the inner
element each time the element is cleaned.
CLEANING OR REPLACING OUTER ELEMENT
1. Open the left engine side cover.
2. Remove three clips (2), then remove cover (3).
NOTICE
Never remove inner element (5). If it is removed, dust will
enter and cause engine trouble.
3. Remove outer element (4).
4-21
SERVICE PROCEDURE MAINTENANCE
4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6).
NOTICE
The inner element must not be used again even after
cleaning. When replacing the outer element, replace the
inner element at the same time.
5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2))

from the inside of the outer element along its folds. Then
direct the compressed air from the outside along the folds,
and again from the inside.
6. Replace any outer element which has been cleaned 6

times or used for 1 year. Replace the inner element at the
same time.
7. Even if the outer element has not been cleaned 6 times, if

the yellow piston in the dust indicator goes to the 5 kPa
position immediately after cleaning (when the engine is
running at high idling, replace both the inner and the outer
element.
8. If small holes or thinner parts are found on the element

when it is checked by shining a light through it after clean-
ing, replace the element.
NOTICE
When cleaning the element, do not hit or beat it against
anything.
Do not use an element whose folds, gasket or seal are
damaged.
9. Before installing the outer element, check that the inner element is fitted securely. If the inner element is not
fitted securely, push it in properly.
CAUTION
When installing the cover (3), check O-ring (7) and replace
it if there are any scratches or damage.
10. Set the cleaned outer element in position, then secure

cover (3) with mounting clips (2).
4-22
11. Push the button of dust indicator (1) and return the yellow
piston to its original position.
12. Close the left engine side cover.
REPLACING ELEMENT
1. Open the left engine side cover.
2. Remove three clips (2), then remove cover (3).
3. Remove outer element (4).
Do not remove inner element (5) at this time, however.
4. Clean the interior of the air cleaner body, cover (3) and
evacuator valve (6).
NOTICE
If the outer element and cover are installed when the inner
element is not installed properly, the outer element may
break.
When installation is correct, protrusion “a“ of the inner
element from the air cleaner body is 35 mm.
5. Remove inner element (5), then quickly install the new

inner element.
Push the inner element in properly and check that it is fitted

securely.
6. Set the new outer element (4) in position.
4-23
7. Replace O-ring (7) for cover (3) with new one.
8. Set the arrow mark on cover (3) at the top, install to the air
cleaner body, then secure with clip (2).
9. Push the button of dust indicator (1) and return the yellow
piston to its original position.
REMARK
Immediately after a new element has been installed, the yellow
piston of the dust indicator may go to the 2nd position, but this
does not indicate any abnormality.
10. Close the left engine side cover.
CLEAN INSIDE OF COOLING SYSTEM 4
WARNING
q Just after the engine is stopped, the coolant is still hot and the internal pressure in the radiator is still
high. If the radiator cap is removed under this condition, you may scald yourself. Accordingly, wait
until the temperature goes down, then loosen the cap slowly to release the pressure.
q Start the engine to clean the cooling system. When standing up from the operator's seat or leaving the
machine, set the work equipment lock lever and parking brake lever to the LOCK positions.
q For the starting method of the engine, see “CHECK BEFORE STARTING ENGINE, ADJUST (3-53)“ and
“STARTING ENGINE (3-68)“ in the OPERATION section of the manual.
q Never go under the machine body while the engine is running. It is very dangerous since the machine
may move suddenly.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the
table below.
Interval of cleaning inside of cooling system

Antifreeze coolant Replacing corrosion resistor
and changing antifreeze coolant
Komatsu supercoolant Every two years or every 4000 hours Every 1000 hours
(AF-NAC) whichever comes first and when cleaning the inside
Permanent type antifreeze Every year (autumn) or every 2000 hours of the cooling system
(All-season type, *) whichever comes first. and when changing coolant.
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03.
Stop the machine on level ground when cleaning or changing the coolant.
4-24
The coolant has the important function of preventing corrosion as well as preventing freezing.
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing table given below.
It is actually better to estimate and temperature about 10°C lower when deciding the mixing ratio.
The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (anti-
freeze/total amount of coolant x 100).
The freezing temperature of undiluted antifreeze is -15°C. Do not store undiluted antifreeze at a temperature of
below -15°C.
Mixing rate of water and antifreeze
Min. atmospheric
°C Above -10 -15 -20 -25 -30
temperature
Amount of antifreeze Liters 11.1 13.3 15.2 17.0 18.5
Amount of water Liters 25.9 23.7 21.8 20.0 18.5
WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on
you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Use antifreeze and appropriate water for diluting (for details, see “COOLANT AND WATER FOR DILUTION (4-6)“)
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to supply antifreeze coolant and water.
1. Stop the engine and tighten 2 valves of the corrosion resistor.
4-25
2. Turn radiator cap (1) slowly until it hits the stopper and by
so doing, relieving the internal pressure.
3. Turn radiator cap (1) until it hits the next stopper, while
depressing it. Keep turning the radiator cap (1) until it hits
the last stopper.
4. Put containers to catch the coolant under drain valve (2) at

the bottom of the radiator and under drain valve (3) at the
side of the cylinder block.
Open drain valve (2) and drain valve (3), and drain the
water.
5. After draining the antifreeze solution, close drain valve (2),

(3), then fill with clean water. After the radiator is filled with
water, start and run the engine at low idling speed. After
the water temperature rises above 90°C, run the engine for
about 10 minutes.
6. Stop the engine and open drain valve (2), (3) to drain the water.
7. After draining the water, clean the cooling system with cleaning agent.
For the cleaning method, see the instructions for the cleaning agent.
8. Replace the corrosion resistor, then open 2 valves.
For details of the procedure for replacing the corrosion resistor, see “REPLACE CORROSION RESISTOR
CARTRIDGE (4-64)“.
9. Close drain valve (2), (3).
10. Add coolant mixed with antifreeze until it overflows from the water filler.
Decide the proportions of antifreeze and water according to the table for the mixing rate of water and anti-
freeze.
11. To remove air in the cooling system, run the engine for 5 minutes at low idle, then for 5 minutes at high idle.
(While doing this, leave the radiator cap removed.)
4-26
12. Drain the coolant from sub-tank (4), clean the inside of the
sub-tank, then add water until the coolant level is between
the FULL and LOW marks.
13. Stop the engine, wait for approx. 3 minutes, then add cool-
ant until the coolant level is near the coolant filler port, and
tighten the cap. Check the coolant level and add coolant if
necessary.
CHECK TRACK SHOE TENSION, ADJUST 4

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is
thus necessary to continually inspect the track tension so as to maintain the standard tension.
Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track
becomes clogged with mud, measure with the track clogged with mud).
INSPECTION
Stop the machine on level ground (stop with the transmission in

FORWARD without applying the brake). Then place a straight
bar on the track shoes between the carrier roller and the idler
as shown in the figure, and measure the clearance between
the bar and the grouser at the midpoint. If the clearance (a) is
20 to 30 mm, the tension is standard.
If the track tension is not at the standard value, adjust it in the

following manner.
ADJUSTMENT
WARNING
There is danger of plug (1) flying out under the high inter-
nal pressure of the grease. Never loosen plug (1) more
than 1 turn.
Never loosen any part other than plug (1). Never put your
face in the mounting direction of plug (1).
If the track tension cannot be loosened with the procedure
given here, please contact your Komatsu distributor.
4-27
WHEN INCREASING TENSION
Prepare a grease pump.
1. Pump in grease through grease fitting (2) with a grease

pump.
2. To check that the correct tension has been achieved, move

the machine backwards and forwards.
3. Check the track tension again, and if the tension is not cor-
rect, adjust it again.
4. Continue to pump in grease until S becomes 0 mm. If the

tension is still loose, the pins and bushings are excessively
worn, so they must be either turned or replaced. Please
contact your Komatsu distributor.
WHEN LOOSENING TENSION
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below. If the
track tension is not relieved by this procedure, please contact your Komatsu distributor.
1. Loosen plug (1) gradually to release the grease.
2. When loosening plug (1), turn it a maximum of one turn.
3. If the grease does not come out smoothly, move the

machine forwards and backwards a short distance.
4. Tighten plug (1).
5. To check that the correct tension has been achieved, move

the machine backwards and forwards.
6. Check the track tension again, and if the tension is not cor-
rect, adjust it again.
4-28
CHECK AND TIGHTEN TRACK SHOE BOLTS 4

If the machine is used with track shoe bolts (1) loose, they will
break, so tighten any loose bolts immediately.
METHOD OF TIGHTENING (TRACK SHOE BOLTS)
1. Torque the track shoe bolts to 539 ± 49 N·m (55 ± 5 kg·m). Then ensure the nut and shoes are in close contact
with the link contact surface.
2. After checking, tighten a further. 120° ± 10°.
METHOD OF TIGHTENING (MASTER CONNECTING BOLT)
1. First tighten to a tightening torque of 343 ± 39 N·m (35 ± 4 kgf·m) then check that the link contact surfaces are
in close contact.
2. After checking the link contact surfaces, tighten the bolt by 180° (Allowable range: 0° - 20°).
ORDER FOR TIGHTENING
Tighten the bolts in the order shown in the diagram on the right.
4-29
REVERSE AND REPLACE END BITS AND CUTTING EDGES 4
WARNING
It is dangerous if the work equipment moves during the turning or replacement operation.
Set the work equipment in a stable condition, set the work equipment lock lever to the LOCK position,
then stop the engine.
Reverse or replace the end bits and cutting edges before it is worn out to the blade end.
1. Raise the blade to a proper height, position a block under the frame to prevent the blade from falling.
2. Set the work equipment lock lever to the LOCK position and stop the engine.
3. Measure the wear of the end bit and cutting edge in accordance with the wear standards given below.
Wear standards
Judgement criteria
Item
(mm)
Allowable
Dimension to be Work Basic
No. max.
measured equipment dimension
value
A,G 242 187
B,C 204 187
Height of end bit
1 D 292 237
(outside)
E,F 315 237
H 222 204
A,B,C 325 300
D 435 410
2 Width of end bit
E,F 540 515
G,H 325 310
A,B,C,G 204 187
Height of end bit
3 D,E,F 254 237
(inside)
H 222 204
Height of cutting edge
4 (Center of bolt A to H 102 85
mounting hole to edge)
The symbols in the work equipment column have the following
meaning.
A: Powertilt dozer (D65EX)
B: Powertilt dozer (D65PX)
C: Powertilt, Power pitch dozer (D65PX)
D: Semi-U blade (3m)(D65EX)
E: Semi-U blade (D65EX)
F: Semi-U blade (D65WX)
G: Angledozer (D65EX)
H: Angledozer (D65PX)
REMARK
If the cutting edge and the end bit on both sides are worn out, replace with new ones.
If it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace.
4. Remove the cutting edge and the end bit and clean the mounting surface.
4-30
5. Reverse or replace the cutting edge and the end bit when worn out.
6. Remove nut (1) and bolt (2), then replace or reverse the
cutting edge and the end bit.
7. Install the cutting edge on the blade and tighten the bolt
temporarily. Press the blade against the ground to elimi-
nate the play of bolt (2), then tighten the bolt to the speci-
fied torque.
Nut tightening torque:
Powertilt dozer : 461 ± 69 N·m (47 ± 7 kgf·m)
Powertilt, Power pitch dozer : 461 ± 69 N·m (47 ± 7 kgf·m)
Angledozer : 441 ± 49 N·m (45 ± 5 kgf·m)
Semi-U dozer :
Cutting edge : 461 ± 69 N·m (47 ± 7 kgf·m)
End bit : 745 ± 108 N·m (76 ± 11 kgf·m)
If bolt (2) and nut (1) are damaged, replace them with new ones at the same time.
8. After several hours of running, retourque the nuts.
4-31
CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND

AFTER-COOLER 4
If the radiator fins are clogged or dirty, clean and inspect them.
CLEANING BY COOLING FAN REVERSE TURN
NOTICE
q When turning the cooling fan in the reverse direction,
be careful of dirt that is sent flying around.
q Leave open the right and left engine side covers so

that dirt does not accumulate in the engine room.
q When stopping the engine while the cooling fan is

turning in the reverse direction, first reduce the engine
rotation to a low idling speed and then stop it.
The dust and dirt stuck to the radiator and cooler can be blown
out by rotating the cooling fan in the reverse direction.
1. Turn starting switch (1) to the OFF position and stop the engine.
2. Turn starting switch (1) to the ON position.
3. Set fan rotation selector switch (2) to the cleaning position

(CLN).
Cooling fan operation checking lamp (3) lights up.
REMARK
Even if it is attempted to reverse a rotation direction of the cool-
ing fan while the engine is running, the rotation direction cannot
be changed.
In that case, cooling fan operation checking lamp (3) flashes
and warns that the fan rotation cannot be reversed.
4. Turn engine starting switch key (1) to the ON position to start up the engine. Then the cooling fan begins to
rotate in the reverse direction.
5. Run the engine at high idle.
Select the time for running the engine at high idle as follows according to the condition of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
4-32
6. After completing the cleaning, run the engine at low idle for approx. 10 seconds.
7. Turn starting switch (1) to the OFF position and stop the engine.
8. Turn starting switch (1) to the ON position.
9. Check first that cooling fan operation checking lamp (3) is unlighted and then start up the engine. The cooling
fan begins to turn in the normal direction.
CLEANING WITH COMPRESSED AIR
WARNING
q Directing compressed air, pressurized water, or steam directly at your body, or using these and caus-
ing dust to fly may cause personal injury. Always wear protective glasses, anti-dust mask, and other
protective equipment.
q When carrying out cleaning, always stop the engine and check that the fan is not rotating. If you touch
the fan when it is rotating, it will cause serious personal injury.
CLEANING OF RADIATOR FINS AND AFTER-COOLER FINS
When the radiator fins and after-cooler fins are clogged or lots of dust is accumulated, clean them with com-
pressed air.
1. Remove bolts (1) (4 bolts).
2. Open the A side (hinge side) of the radiator mask. It opens

approx. 10 mm.
3. Open the B side of the radiator mask.
4. Blow off dirt, dust and dry leaf shreds clogging the radiator
fins and after-cooler fins with compressed air. Steam and
water may also be used for cleaning instead of com-
pressed air.
REMARK
Check the hydraulic cooler hoses. If any hose is cracked or
hardened by age, replace with a new hose. Also check and
tighten all loose hose clamps.
5. When closing the radiator mask, always push in the A side

first, then push in the B side, align the bolt holes, and
tighten bolts (1).
4-33
CLEANING OF OIL COOLER FINS AND CONDENSER FINS
When the oil cooler fins and condenser fins are clogged or lots of dust is accumulated, clean them with com-
pressed air.
1. Open up right and left side covers (1).
2. Remove right and left bolts (3) - 4 bolts in total - to remove

right and left lower side covers (5).
3. Remove right and left bolts (4) - 8 bolts in total - to remove

right and left small side covers (6).
4. Remove bolts (2) - 2 bolts in total - to remove sub-tank

assembly together with stay (7).
5. Put the removed sub-tank assembly on radiator guard seat

(8) and temporarily fasten it to radiator guard seat (9) with
removed bolt (2) - 1 bolt only.
4-34
6. Remove right and left bolts (11) - 2 bolts in total, and loosen
bolts (12) - 2 bolts in total - to swing back oil cooler (9) and
air conditioner condenser (10).
7. Blow off dirt, dust and dry leaf shreds clogging the oil
cooler fins and air conditioner condenser fins with com-
pressed air. Steam and water may also be used for clean-
ing instead of compressed air.
8. Put oil cooler (9) and air conditioner condenser (10) back
to the original position by swinging them forth, tighten bolts
(12) and install bolts (11).
9. Reassemble the temporarily fastened sub-tank assembly

in the original position.
10. Install right and left lower side covers (5) and small side
covers (6) and close the engine side covers.
CHECK, ADJUST AIR CONDITIONER 4

CHECKING TENSION OF COMPRESSOR BELT
If the driving belt slackens, it is likely to slip, lowering the cool-

ing efficiency. Depress the mid point between drive pulley (1)
and compressor pulley (2) with a thumb (approx. 98 N (10 kg))
every now and then to make sure that deflection amount (A) is
approx. 15 mm to 18 mm.
When it is a new belt, elongation is expected in the initial period

of use, so be sure to make an adjustment in a few days after
the replacement.
4-35
CHECK LEVEL OF REFRIGERANT
WARNING
If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of
sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is leaking.
If the level of the refrigerant (gas) is low, the cooling effect will
be reduced. Run the engine at high idle, and check the flow of
the refrigerant gas (freon 134a) in the refrigerant circuit through
the sight glass (2) (inspection window) of the receiver (1) when
the cooler is running at high speed.
q (A) Correct: No bubbles are included in the flow
q (B) Low: Bubbles are included in the flow
(bubbles pass continuously)
q (C) None: Colorless, transparent
REMARK
When there are bubbles, the refrigerant gas level is low, so
contact your refrigerant dealer to have refrigerant added. If the
air conditioner is run with the refrigerant gas level low, it will
cause damage to the compressor.
New Freon R134a is used as the refrigerant.
OPERATING AIR CONDITIONER OFF-SEASON
Even during the off-season, operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all
parts of the compressor.
GREASE DOOR HINGE 4

If the door makes a squeaking noise when it is opened or

closed, spray lubricant in through the split in the hinge bushing.
If the bushing is worn, replace the hinge.
4-36
CHECK DOOR LOCK STRIKER 4

If wear (A) of the door of lock striker exceeds 0.5 mm, replace
the striker. If it is used as it is, the play will increase and this
may result in breakage of the hinge or door lock.
REPLACE DOOR DAMPER 4

If depth (A) of the groove of door damper rubber (1) is less than
2 mm, replace the damper.
There are 4 dampers: 1 each at the top and bottom on the left
and right doors.
CHECK DOOR LATCH 4

Hold the door open and check that there is still grease inside
the latch. If the amount of grease is low or there is no more
grease, coat the inside of the latch with grease from portion (1).
REMARK
If there is no more grease inside the latch, the movement will
become poor because of dust inside the latch, and the handle
may be stiff when opening the door.
4-37
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 4

If there is air in the window washer fluid, check the level and
add fluid.
Open the engine side cover on the right side, check the level of
the fluid in window washer tank(1), and if it is low, add automo-
bile window washer fluid.
When adding fluid, be careful not to let any dust get in.
PROPORTION FOR MIXING FLUID WITH WATER
The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following
proportions before adding.
Area, season Proportions Freezing temperature

Normal Washer fluid 1/3: water 2/3 -10°C
Winter in cold area Washer fluid 1/2 : water 1/2 -20°C
Winter in extremely
Pure washer fluid -30°C
cold area
There are two types depending on the freezing temperature:
-10°C (general use) and -30°C (cold area use), select according to the area and season.
4-38
REPLACE WIPER BLADE 4

If the blade is damaged, it will not wipe the window clean, so

replace the blade.
REPLACEMENT
FRONT, DOOR WIPER
1. It is hooked at portion (A), so move the blade in the direc-

tion of the arrow to remove it.
2. Install the new blade and hook it securely.
REAR WIPER
1. Remove E-ring (1).
The blade can then be removed.
2. Install a new blade, then install securely with E-ring (1).
4-39
CHECK IDLER OIL LEVEL, ADD OIL 4
WARNING
If the oil level in the idler is low, new oil must be added, and the machine body must be inclined in this
case. Since this work is dangerous, ask your Komatsu distributor.
If the oil level in the idler is low, noise will be generated and there will be seizure, so check the oil level and add oil
as follows.
INSPECTION
1. Remove bolt (1), then remove guide plate (2) and shim (3).
REMARK
When removing shim (3) keep it in a safe place and be careful
not to lose it.
2. Loosen plug (4) slowly. If oil oozes through the threads at

this time, the quantity of oil is sufficient. Tighten plug (4).
3. If any oil does not flow out when plug (4) is removed, the
quantity of oil is insufficient. In this case, ask your Komatsu
distributor for repair.
4. Install guide plate (2) and shim (3) with bolt (1).
REMARK
When installing guide plate (2), install the same number and
thickness of shim (3) as removed in Step 1.
The optimum clearance may be obtained, if the adjustment is
made at the same time. For details of adjusting the shim thick-
ness, see “ADJUST IDLER CLEARANCE (4-40)“.
ADJUST IDLER CLEARANCE 4

Since the idlers are forced to move forward and backward by an external force guide plates will be worn out.
Wear of these plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off of
track links from the idlers or unevenly worn idler and links may result.
Therefore, adjust the idlers according to the following procedure.
4-40
ADJUSTMENT
1. Travel for 1 or 2 meters on flat ground, then measure clear-

ance (A) between track frame (1) and guide plate (2) (4
places: left, right, inside, outside).
2. If the clearance (A) exceeds 4.0 mm, loosen bolt (3), and
pull out the shim to adjust the clearance at one end to 0.5
to 1.0 mm.
Thickness of one shim is 1.0 mm.
LUBRICATING UNIVERSAL JOINT 4
WARNING
The undercover is heavy. Never try to open or close the cover when directly beneath it. When removing
bolts (2), carry out the work from the rear of the cover so that you can easily get out of the way.
1. Remove the undercover from the rear bottom of the

machine body as follows.
2. Remove two bolts (1) from the front side of the machine
body.
3. Holding the cover, remove two bolts (2) from the rear side
of the machine body.
4. Lower and open the cover gradually.
(A) Front of machine
(B) Dangerous place
5. Apply grease to the grease fittings (2 places) shown by

arrows.
4-41
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM 4

See “STARTING ENGINE (3-68)“.
Since the engine must be started and the blade must be operated, see OPERATION.
NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air
taken inside the cylinder may cause damage to the piston packing.
1. Bleed air from left pitch cylinder
(Powertilt, Power pitch dozer only)
Bleeding air from the hydraulic system is required when removing and installing the work equipment or when
making the repairs.
2. Start the engine and run it at low idle for at about 5 min-
utes.
3. Raise the blade.
4. Bleeding air in the tilt hydraulic circuit by repeating left and

right tilt operation five to ten times.
5. Bleeding air from the bottom of left cylinder by operating

the blade to pitch forward and backward 5 to 10 times
repeatedly.
6. Set the left and right cylinders at the neutral position, then
carry out the following operations 5 to 10 times to bleed the
air from the head end of the left pitch cylinder.
(1) Forward pitch → (2) Left tilt → (3) Right tilt → (4) Backward pitch
7. Bleeding air from cylinders
8. Run the engine at low idle, and extend and retract each
cylinder 4 to 5 times, taking care that a cylinder is not
moved to the end of its stroke. (Stop the cylinder approx.
100 mm short of its stroke end)
9. Next, operate each cylinder 3 to 4 times to the end of its

stroke.
10. Finally, operate each cylinder 4 to 5 times to the end of its

stroke to completely remove the air.
4-42

For details of the following items, see “CHECK BEFORE STARTING (3-54)“ in the OPERATION section.
q Check oil level in engine oil pan, add oil
q Check dust indicator
q Check, drain water separator
q Check coolant level, add coolant
q Check oil level in power train case, add oil
q Check electric wiring
q Check brake pedal travel
q Checking with machine monitor
q Check fuel level, add fuel
q Check horn sound
q Check that lamps light up
q Check of operation of backup alarm
DRAIN WATER, SEDIMENT FROM FUEL TANK 4

Carry out this check before operating the machine.
q Prepare a container to catch the fuel that is drained.
1. Open cover (1).
2. Open valve (2) at the bottom of the tank and drain the sed-
iment and water that has accumulated at the tank bottom
together with fuel.
When doing this, be careful not to get fuel on yourself.
3. When clean fuel comes out, close drain valve (2).
4-43

Maintenance for every 50 hours service should be carried out at the same time.
LUBRICATING 4
1. Lower the blade to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.
POWER TILTDOZER
(1) Lift cylinder support yoke (4 places)
(2) Lift cylinder support shaft (2 places)
(3) Lift cylinder ball joint (2 places)
(4) Tilt cylinder ball joint (1 place)
(5) Tilt brace ball joint (1 place)
(6) Brace ball joint (2 places)
(7) Tilt brace thread (1 place) (screw-adjustable)
POWER TILT-POWER PITCH DOZER
4-44
(4) Tilt cylinder ball joint (1 place)
(5) Pitch cylinder ball joint (1 place)
(6) Brace ball joint (2 places)
ANGLEDOZER
(4) Tilt brace ball joint (2 places)
(5) Tilt brace thread (2 places)
GREASE EQUALIZER BAR SIDE PIN 4

Left and right, 1 places each
1. Remove all dirt from the top of the track frame and cover.
2. Clean the grease fitting indicated with the arrow, then sup-
ply grease to that fitting with a grease pump.
REMARK
Supply 3 shots of grease (Operate the grease pump lever 3
times) to each grease fitting, and check that grease is newly
discharged through the seal lip.
If grease is not newly discharged through the lip, continue sup-
plying grease until it is discharged.
4-45
GREASE EQUALIZER BAR CENTER PIN 4

(1 place)
1. Open the engine side cover on the left side of the chassis.
2. Clean the grease fitting indicated with the arrow, then sup-
ply grease to that fitting with a grease pump.
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 4
WARNING
q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool
down before starting the operation.
q If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.
1. Stop the machine so that drain plug (3) is directly at the

bottom.
2. Remove oil level plug (2) and check whether the final drive
case is filled with oil to lower edge of the plug hole.
3. If the oil level is too low, add oil through the oil filler plug
hole (1).
4. When oil starts to overflow from oil level plug (2), stop filling
and install oil level plug (2) and oil filler plug (1).
4-46
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 4
WARNING
q The parts and oil are at high temperature immediately after the engine is stopped, and may cause
burns. Wait for the temperature to go down before starting the work.
q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
NOTICE
q Do not add oil if the level is above the H line. This will
damage the hydraulic equipment and cause the oil to
spurt out.
q Always lock the cap with the key.
1. Lower blade to the ground and stop the engine. Wait for 5
minutes before checking oil level. Oil level should be
between the H and L in sight gauge (G).
2. If the level is below the L mark, add oil through oil filler (F).
3. After adding oil, be sure to screw on the oil filler cap and
lock it with the key.
4-47
CHECK LEVEL OF BATTERY ELECTROLYTE 4

Perform this check before operating the machine.
WARNING
q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler-
ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may cause an explosion.
q The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near
the battery.
q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
q When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY
If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Open the battery cover on the left side of the machine body.
2. Use a wet cloth to clean the area around the electrolyte

level lines and check that the electrolyte level is between
the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
If the battery is wiped with a dry cloth, static electricity may

cause a fire or explosion.
3. If the electrolyte level is below the midway point between

the U.L. and L.L. lines, remove cap (1) and add distilled
water to the U.L. line.
4. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the U.L. line, use a syringe
to lower the level to the U.L. line. Neutralize the removed fluid
with baking soda (sodium bicarbonate), then flush it away with
a large amount of water or consult your Komatsu distributor or
battery maker.
4-48
WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY
If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Open the battery cover on the left side of the machine body.
2. Remove cap (1) at the top of the battery, look through the
water filler port (2), and check the electrolyte surface. If the
electrolyte does not reach the sleeve (3), add distilled
water so that the level reaches the bottom of the sleeve
(UPPER LEVEL line) without fail.
q (A) Suitable level: Electrolyte level is up to bottom of

sleeve, so surface tension causes electrolyte surface
to bulge and poles appear bent.
q (B) Low: Electrolyte level is not up to bottom of sleeve,

so poles appear straight and not bent.
3. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the bottom of the sleeve,
use a syringe to lower the level to the bottom of the sleeve.
Neutralize the removed fluid with baking soda (sodium bicar-
bonate), then flush it away with a large amount of water or con-
sult your Komatsu distributor or battery maker.
WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL
If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
CHECK, CLEAN ADDITIONAL FUEL STRAINER 4

(If equipped)
1. Open cover (1).
2. Close fuel supply valve (2), then remove strainer cap (3).
The strainer forms one unit with the strainer cap.
3. Remove any dirt stuck to the strainer, then wash in clean

diesel fuel or flushing oil. If the strainer is damaged,
replace it.
4. After checking and cleaning, install the strainer, then

tighten cap (3).
5. After installing, open fuel supply valve (2).
4-49
CHECK BRAKE PERFORMANCE 4
WARNING
If the machine moves during the following operation, please contact your Komatsu distributor for repairs
immediately.
NOTICE
Do not place the gear shift lever in 1st under any circumstances. The machine will be damaged.
Before starting the engine, check that the area around the machine is safe, then do as follows:
2. Set work equipment lock lever (1) to the FREE position (F)
then operate blade control lever (2) to raise the blade.
Leave the work equipment lock lever(1) to the FREE posi-

tion (F).
3. Set parking brake lever (3) to the FREE position (F).
4. Depress brake pedal (4), set steering, forward-reverse,

gear shift lever (5) in FORWARD, then press the shift up
button to enter 2nd speed.
5. Operate fuel control dial (6) and gradually raise the engine
speed to full throttle. (Keep the brake pedal depressed.)
6. Check that the machine does not move. This indicates that
brake performance is normal.
4-50
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) 4

Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it.
In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter
at the same time, when cleaning the engine air cleaner.
1. Loosen mounting bolts (1), pull up inspection cover (2) to

the rear, and remove it.
2. Remove inside cover (3), then remove FRESH filter (4).
3. Remove the filter box, then brush out the dirt accumulated
inside the box through the cleaning hole (5) in the hood.
When doing this, be careful not to let any dirt or dust get
into the fresh air intake port (6) leading to the cab.
4. Open inspection cover (7) under the front panel, then pull
up RECIRC filter (8) and remove it.
5. Clean filters(4) and (8) with compressed air.
If the filters are stained with oil or extremely dirty, wash

them in neutral detergent.
After washing the filters, dry them up, then install them.
REMARK
If the filters cannot be cleaned with air or in water, replace them
with new ones.
4-51

Maintenance for every 50 and 250 hours service should be carried out at the same time.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious
burns. Wait for the oil temperature to go down before performing this operation.
q Refill capacity: 28 liters
q Prepare a socket wrench and filter wrench.
1. Remove the cover (1) on the bottom of the machine and

set a container to catch the drained oil directly under the
drain plug.
2. Take the end of hose (2) out of the inspection window.
3. Loosen drain plug (P) to drain oil. Do it slowly so that you

do not get splashed with drained oil.
4. Check the drained oil, and if there are excessive metal par-
ticles or foreign material, please contact your Komatsu dis-
tributor.
5. Install drain plug (P).
6. Open the engine side cover on the right side of the

machine.
7. Remove bolts (3) - 2 bolts in total - to remove lower side

cover (4).
4-52
8. Remove bolts (5) - 4 bolts in total - to remove washer tank

assembly (6).
9. Turn engine oil filter cartridge (7) to the left with a filter
wrench.
10. Clean the filter holder, fill the new filter cartridge with clean
oil, coat the thread and packing portion of the new filter car-
tridge with oil (or coat thinly with grease), then install.
11. When installing the filter cartridge, bring the packing sur-
face into contact with the filter holder, then tighten a further
3/4 to 1 turn.
12. After replacing the filter cartridge, add oil through oil filler
(F) until the oil level is between the H and L marks on the
dipstick (G).
13. Run the engine at idle for a short time, then stop the
engine, and check that the oil level is between the H and L
marks on the dipstick. For details, see “CHECK OIL LEVEL
IN ENGINE OIL PAN, ADD OIL (3-54)“.
4-53
REPLACE POWER TRAIN OIL FILTER ELEMENT 4
WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.
2. Remove bolts (1) (4 bolts), then remove cover (2).
3. Remove the grommet under the fender, loosen drain plug

(P), and drain the oil from inside the filter case.
4. Take out plate (3), element (4), valve (5), and spring (6).
5. Clean the inside of the case, then wash plate (3), valve (5),
and spring (6).
6. Install spring (6), valve (5), new element (4), and plate (3).
7. Replace O-ring (8) with a new part, then install cover (2)
with bolt (1).
8. Install drain plug (P).
9. Loosen air vent plug (7) and start engine. Tighten the plug
when oil comes out.
REPLACE FUEL PRE-FILTER CARTRIDGE 4
WARNING
q After the engine has been operated, all parts are at high temperature, so do not replace the filter imme-
diately. Wait for all parts to cool down before starting the operation.
q High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pres-
sure go down before replacing the filter.
q Do not bring any fire or flame close.
NOTICE
q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing the filter cartridge, always use a genuine Komatsu part.
q The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause
problems with the injection system. Always avoid using substitute parts.
q When carrying out inspection or maintenance of the fuel system, pay more attention than normal to
the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.
4-54
Prepare a filter wrench and a container to catch the fuel.
1. Open the inspection cover at the bottom of the fuel tank.
2. Close fuel tank valve (1).

machine.
4. Put a container under filter cartridge (4) to receive drained

oil.
5. Disconnect connector (2) from the water separator lamp.
6. Turn transparent cap (3) to the left with a filter wrench.

(This cap is to be used again, so replace it with a new one
if there is any damage on it.)
7. Using a filter wrench, turn cartridge (4) to the left to remove

it.
8. Clean the filter base, and coat with oil the contact face of a
new filter with the packing.
9. Install a new filter cartridge without t fuel.
When installing the cartridge, turn it by 3/4 of a turn after

the packing comes to contact with the filter base sealing
face.
If the cartridge is tightened too tightly, the packing can be

damaged, causing fuel to leak. On the other hand, if it is
tightened loosely, fuel can also leak through a clearance
between the packing and the base. Therefore, be sure to
follow the specified tightening angle.
10. Fix earlier removed cap (3) to the base of a new filter car-
tridge.
At that time, be sure to replace the seal ring with a new

one.
q Specified tightening torque of transparent cap: 11 N·m

(1.0 kg·m)
When the seal ring has been replaced, coat the surface
with clean fuel before installing it.
11. Make sure that drain plug (5), which is provided in the
lower part of transparent plug (3), is firmly tightened.
Specified tightening torque of drain plug: 0.2 to 0.45 N·m

(0.02 to 0.046 kg·m)
4-55
12. Connect connector (2) to the water separator.
13. Open fuel tank valve (1).
14. Bleed air from fuel filter cartridge (4) after the replacement.
Bleed the air as follows:
begins to work.

onds.
17. Repeat the operation in Step 15 and 16 four times.
to start up the engine, check the filter sealing face and
water separator installing face for fuel leak and run the
engine at low idling for approx. 10 minutes.
4-56

Maintenance for every 50, 250 and 500 hours should be carried out at the same time.
REPLACE FUEL MAIN FILTER CARTRIDGE 4

Carry out this operation after carrying out the maintenance in the “REPLACE FUEL PRE-FILTER CARTRIDGE (4-
54)“ for every 500 hours.
WARNING
q After the engine has been operated, all parts are at high temperature, so do not replace the filter imme-
diately. Wait for all parts to cool down before starting the operation.
q High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pres-
sure go down before replacing the filter.
q Do not bring any fire or flame close.
NOTICE
q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing the filter cartridge, always use a genuine Komatsu part.
q The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause
problems with the injection system. Always avoid using substitute parts.
q When carrying out inspection or maintenance of the fuel system, pay more attention than normal to
the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.
Prepare a filter wrench and a container to catch the fuel.
1. Open the inspection cover at the bottom of the fuel tank.
2. Close fuel tank valve (1).
4-57

machine.
4. Remove bolts (2) - 2 bolts in total- to remove lower side

cover (3).
5. Put a container under filter cartridge (4) to receive drained

oil.

it.
NOTICE
q Do not fill the new filter cartridge with fuel.
q Remove cap (B) and install the filter cartridge.
7. Clean the filter holder, coat the packing surface of the new
filter cartridge thinly with oil, then install the filter cartridge
to the filter holder.
8. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/
4 of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
9. Open fuel tank valve (1).
10. Bleed air from fuel filter cartridge (4) after the replacement.
Bleed the air as follows:
4-58
begins to work.

onds.
13. Repeat the operation in Step 12 and 13 four times.
to start up the engine and check the filter sealing face for
fuel leak. If leak is noticed, check the filter cartridge for its
tightening condition. If it is correctly tightened and fuel still
leaks, remove the filter cartridge once and check the con-
tact face with the packing for damage or any caught- in for-
eign material. If any, replace it with a new one.
4-59
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP
STRAINER, SCAVENGING PUMP STRAINER) 4
WARNING
q The undercover is heavy. Never try to open or close the cover when directly beneath it. When remov-
ing bolts (3), carry out the work from the rear of the cover so that you can easily get out of the way.
1. Remove cover (1) at the bottom rear of the machine.
2. Loosen drain plug (P) (with slit) and drain the oil.
After draining the oil, tighten drain plug (P).

body.
(B) Dangerous place
4-60
7. Loosen mounting bolt (4) of the power train strainer, then

remove cover (5).
8. Take out spring (6), then take out strainer (7).
9. Remove all dirt from strainer (7), then wash in clean diesel
oil or flushing oil. Clean the case interior and the removed
parts.
10. Loosen mounting bolt (8) of the scavenging pump strainer,

then remove cover (9).
11. Take out spring (10), then take out strainer (11).
12. Remove all dirt from strainer (11), then wash in clean diesel
oil or flushing oil. Clean the case interior and the removed
parts.
If the spring or strainer are damaged, replace them.
13. Install the strainers in their original position.
14. After installing, replace the element in the power train oil filter. For details, see “REPLACE POWER TRAIN OIL
FILTER ELEMENT (4-54)“.
16. Refill the specified quantity of oil through oil filler (F).
17. Check that the oil is at the specified level. For details, see
“CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL
(3-58)“.
18. Close the cover at right side of machine.
4-61
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4
WARNING
q The oil is at high temperature immediately after the
machine has been operated. Wait for the oil to cool
q The undercover is heavy. Never try to open or close

the cover when directly beneath it. When removing
bolts (2), carry out the work from the rear of the cover
so that you can easily get out of the way.
If the quantity of the oil in the damper is insufficient, the damper may be seized. Accordingly, check, and add or
replace the oil according to the following procedure.

body.
(B) Dangerous place
5. Remove oil level plug (3) and check the oil level. The
proper oil level is the bottom edge of the plug hole.
Tighten plug (3).
REMARK
Check the oil level while the engine is stopped.
If the machine is inclined, set it in a level position before check-
ing the oil level.
6. If the oil level is below the bottom edge of the plug hole,
remove oil filler plug (4) and add new oil.
Add new oil until the oil level reaches the bottom edge of oil
level plug (3).
7. After adding the oil, tighten plugs (3) and (4).
4-62
CHANGE OIL IN FINAL DRIVE CASE 4
WARNING
q If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.
q Refill capacity:
D65EX : (each) 24 liters
D65PX,WX: (each) 27 liters
1. Stop the machine so that drain plug (3) is directly at the

bottom.
2. Remove oil level plug (2) and oil filler plug (1), then remove
drain plugs (3) and (4), and drain the oil.
3. After draining the oil, install drain plugs (3) and (4).
4. Add oil to the specified level through the hole in oil filler
plug (1).
“CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL (4-
46)“.
CLEAN BREATHER 4
2. Remove breather (1), then use clean diesel fuel or flushing

fluid to rinse the dirt out from the inside.
4-63
REPLACE CORROSION RESISTOR CARTRIDGE 4

Use Komatsu genuine cartridge.
1. Screw in 2 valves (1) at the top of the corrosion resistor.

it.
3. Apply engine oil to the sealing surface of a new cartridge,

then install it to the filter holder.
4. When installing, screw in cartridge until seal comes in con-

tact with sealing surface, then tighten approx. 2/3 turn.
5. Open valves (1) (2 places).
CHECK FOR LOOSE ROPS MOUNT BOLTS 4

Check that the bolts are not loose and that there is no damage.
If any bolt is loose, tighten it to the following torque.
If there is any damage, replace the bolt with a genuine Komatsu part.
Tightening torque: 785 to 980 N·m (80 to 100 kgf·m)
INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS 4

Check each clamp for loosening. If any clamp is found loosened, tighten it further.
4-64

Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT 4
WARNING
1. Lower the work equipment to the ground, then stop the

engine.
2. Turn the cap of oil filler (F) slowly to release the internal
pressure, then remove the cap.
3. Remove the cover (1) at the bottom of the hydraulic tank.
4. Loosen drain valve (2), drain the oil, tighten drain valve (2)
again, then install cover (1). When loosening drain valve
(2), be careful not to get oil on yourself.
5. Remove bolt (3), then remove cover (4).
6. Take out spring (5), valve (6), and element (7).
7. Clean the inside of the case, then wash spring (5) and
valve (6).
8. Install new element (7), valve (6), and spring (5).
9. Install cover (4) with bolt (3).
10. Refill the specified quantity of oil through oil filler (F).
“CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (4-
47)“.
4-65
REPLACE HYDRAULIC TANK BREATHER ELEMENT 4
WARNING
1. Remove the cap of oil filler (F) at the top of the hydraulic
tank.
2. Replace element (1) inside the cap.
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CON-

TROL CIRCUIT) 4
WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo-
sion, which will lead to serious injury or damage. When handling the accumulator, always do as follows.
The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equip-
ment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition,
loosen the bolts slowly when carrying out the operation.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to
have this work carried out.
4-66
FUNCTION OF ACCUMULATOR 4
The accumulator stores the pressure in the control circuit.
Even after the engine is stopped, the control circuit can be
operated, so the following actions are possible.
q If the control lever is operated in the direction to lower the

work equipment, it is possible for the work equipment to go
down under its own weight.
q The pressure in the hydraulic circuit can be released.
The accumulator is installed to the position shown in the dia-

gram on the right.
CHECKING FUNCTION OF ACCUMULATOR 4

Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner.
Check the nitrogen gas charge pressure as follows.
1. Stop the machine on firm, level ground.
2. Operate the parking brake lever to LOCK position (L).
3. Raise the work equipment (blade) to the maximum height.
NOTICE
Carry out the following procedure for lowering the blade to the ground within 15 seconds after stopping
the engine.
When the engine is stopped, the pressure inside the accumulator gradually goes down, so this inspection
can be carried out only immediately after the engine is stopped.
4-67
4. While holding the work equipment at the highest position,

turn the engine starting switch key to OFF position (A).
5. Turn the engine starting switch key to ON position (B).
6. Turn the work equipment lock lever to FREE position (F).
7. Operate the blade control lever fully in the direction to

lower the blade.
REMARK
Check that the area around the machine is safe, then operate
the blade control lever to the LOWER position.
8. Check that the work equipment goes down to the ground

under its own weight.
9. This completes the inspection.
NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become
impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the
machine.
In the following cases, the charge pressure of the accumulator has gone down. Please contact your Komatsu dis-
tributor.
q Work equipment does not go down
q Stops while going down
4-68
METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT 4

NOTICE
Finish the steps of operating the blade control lever to the front and back, and to the right and left, to each
stroke end within 15 seconds after the engine has stopped. After the engine stops, pressure inside the
accumulator begins to gradually go down, so the pressure cannot be released except right after the
engine stops.
1. Lower the work equipment and stop the engine.
2. Turn the starting switch to the ON position.
3. Set the work equipment lock lever to the FREE position.
4. Operate the blade control lever fully to the front, rear, left,
and right to release the pressure from the hydraulic circuit.
In order to release pressure from the ripper hydraulic cir-

cuit, operate the ripper control lever to the right and left to
each stroke end. (A) RAISE
(B) LOWER
(C) FLOAT
(D) LEFT TILT
5. Set the work equipment lock lever to the LOCK position.
(E) RIGHT TILT
CHANGE OIL IN DAMPER CASE 4
WARNING
q The parts and oil is very hot just after the operation.
Wait until the oil temperature drops, then start the
work.
q The undercover is heavy. Never try to open or close

the cover when directly beneath it. When removing
bolts (2), carry out the work from the rear of the cover
so that you can easily get out of the way.
q When removing drain plug (5) of the damper case, take

care not to get oil over yourself.
q Quantity of replacement oil: 1.3 liters

body.
(B) Dangerous place
4-69
5. Remove oil level plug (3) and oil filler plug (4), then remove
drain plug (5) to drain the oil. After the all oil is drained,
tighten plug (5).
6. Add oil through the hole of oil filler plug (4) until the oil level
reaches the bottom edge of the hole of oil level plug (3).
7. After refilling the oil, tighten plugs (3) and (4).
CHECK VIBRATION DAMPER 4

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
CHECK ENGINE VALVE CLEARANCE, ADJUST 4

Special tools are needed for inspection and maintenance, please contact your Komatsu distributor.
4-70

Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) 4

Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner.
WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo-
sion, which will lead to serious injury or damage. When handling the accumulator, always do as follows.
The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic equip-
ment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition,
loosen the bolts slowly when carrying out the operation.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to
have this work carried out.
If operations are continued after the performance of the accu-

mulator has dropped, it will be impossible to release the
remaining pressure in the hydraulic circuit if there should be a
failure on the machine. Please ask your Komatsu distributor to
replace the accumulator.
CHECK WATER PUMP 4

Check the water pump and its relative parts for water leak, and if anything abnormal is found, call on your Komatsu
distributor for repairs or replacement.
4-71
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER 4

Check clamp (1) visually or with a finger to see if there is any
loosed bolt, or the rubber portion is hardened. If any such
abnormality is found, call on your Komatsu distributor for
repairs or replacement.
NOTICE
If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is
danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure
piping. Always check that the proper high-pressure piping clamps are correctly installed.
4-72
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4

Check fuel spray prevention caps (1) through (14) visually or with a finger to see if any of them has slipped off, or
the rubber portion is hardened. If any such abnormality is found, call on your Komatsu distributor for repairs or
replacement. Fuel spray prevention caps (1) through (14) are a protective part that serves to prevent leaked fuel
from splashing over highly heated portions of the engine, causing fire as a result.
4-73

Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time.
REPLACE HIGH-PRESSURE PIPING CLAMP 4

Contact your Komatsu distributor to have the engine high-pressure clamps replaced.
REPLACE FUEL SPLAY PREVENTION CAPS 4

Contact your Komatsu distributor to have the fuel spray prevention cap replaced.
4-74
SPECIFICATIONS
15
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS 5
D65EX and D65WX: Semi-U dozer with ROPS guard, cab and air conditioner
D65PX: Power tilt-dozer with ROPS guard, cab and air conditioner
Item Unit D65EX-15 D65PX-15 D65WX-15

Machine weight kg 20,280 21,000 21,140
Name of engine - Komatsu SAA6D114E-3 diesel engine
Engine horsepower (ISO9249) kw{HP}/rpm 153{205}/1,950
A Overall length mm 5,440 5,520 5,440
B Overall height mm 3,220 3,220 3,220
C Overall width mm 3,460 3,970 3,640
Forward km/h 3.3/6.3/10.1
Travel speed (1st/2nd/3rd)
Reverse km/h 4.4/8.2/12.9
5-2
ATTACHMENTS, OPTIONS
16
WARNING
Please read and make sure that you understand the safety
GENERAL PRECAUTIONS ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS 6
PRECAUTIONS RELATED TO SAFETY 6

If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of
the machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu-
tor first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.
WARNING
General precautions
Read the instruction manual for the attachment carefully, and do not use the machine before you under-
stand the operation method completely.
If you lose the instruction manual, be sure to order another copy from your Komatsu distributor.
To prevent serious personal injury caused by misoperation, place your foot on the pedal only when oper-
ating the pedal.
Precautions for removal and installation
When removing or installing an attachment, observe the following items and work safely.
Select a firm, level surface when installing or removing an attachment.
When working in cooperation with one or more other workers, decide signs and observe them when carry-
ing out the operation.
When carrying a heavy part (25 kg or more), use a crane.
When removing a heavy part, always place a support in position before removing it.
When lifting a load with a crane, be particularly careful of the center of gravity.
It is dangerous to carry out operations when the load has been raised by a crane. Always lower the load
onto a stand and check that it is safe.
When leaving an attachment removed or installing it, place it in a stable position to prevent it from falling
over.
Never go under a load raised by a crane.
Always stand in a place which is safe even if the load should fall.
NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per-
son.
For details of removal and installation operations, contact your Komatsu distributor.
6-2
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER
HANDLING HYDRAULIC RIPPER 6

q This hydraulic ripper is for D65EX and D65WX dozers.
GENERAL VIEW 6
(1) Hydraulic cylider (4) Shank

(2) Link (5) Point
(3) Beam (6) Support
6-3
HANDLING HYDRAULIC RIPPER ATTACHMENTS, OPTIONS
EXPLANATION OF COMPONENTS 6
RIPPER CONTROL LEVER
WARNING
When carrying out inspection or maintenance of the machine, or when parking the machine, lower the rip-
per to the ground and set the work equipment lock lever to the LOCK position.
This lever is used to operate the ripper.
(A) RAISE: Ripper goes up
(B) HOLD: Ripper is stopped and held in the same position.
(C) LOWER: Ripper goes down
REMARK
If the work equipment lock lever is set to LOCK position (L), the
operation of the ripper is locked.
For details of the operation of the work equipment lock lever,
see “WORK EQUIPMENT LOCK LEVER (3-33)“.
6-4
OPERATION 6
CHECK BEFORE STARTING ENGINE, ADJUST 6
WALK-AROUND CHECK
1. Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the
rivets. If any problem is found, replace or repair.
PRECAUTIONS WHEN OPERATING 6

q Travel in low speed and lower the ripper gradually when starting to move the machine off. When the optimum
digging depth is reached, move the control lever to the HOLD position.
Do not dig the shank in deep when starting digging operations.
q During ripping operations, never turn the machine suddenly or travel in reverse. When turning the machine
suddenly or traveling in reverse, raise the shank from the ground surface.
q When carrying out digging operations with only one shank, always use the center shank. Remove both side
shanks.
q When starting to travel up a steep slope or when reaching the bottom of the slope, the point may touch the
ground. On hard ground, there is danger of the point breaking if it touches the ground, so raise the shank to
the maximum height.
ADJUSTING POSTURE OF WORK EQUIPMENT 6
ADJUSTMENT OF DIGGING DEPTH
There are mounting holes for the pin in the shank. Select the mounting hole to match the digging depth.
Pin hole Max. digging

Use
position depth
When there is special need to
(A) 595 mm
dig deeply
(B) Normal 485 mm
(C) When not using ripper -
6-5
When changing the digging depth, do as follows.
1. Remove cotter pin (1).
2. Remove pin (2), change the position of the shank hole,

then insert pin (2).
3. Insert cotter pin (1).
ADJUSTING DIGGING ANGLE
Adjust the position of the mounting pin hole in the beam and
upper link.
q Digging angle
Position (1): 45°
Position (2): 55°
The pin is locked with lock plate (3).
REPLACEMENT OF POINT
A point is installed to protect the shank. If the point is worn,

replace it as follows.
1. Put a pin remover in contact with the pin marked by the

arrow and tap with a hammer to remove.
2. Replace the point.
3. Insert the pin half way, then knock it in fully with a hammer.
6-6
TROUBLESHOOTING 6
OTHER TROUBLE 6

Slow ripper raising and function, •Add oil to specified level, see
lack of ripping force EVERY 250 HOURS SERVICE
•Improper hydraulic oil
(•Check, repair)
(•Check, repair)
•Defective pump
•Defective adjustment of relief valve
(•Check, repair)
•Defective control valve, safety valve
•Defective valve spool
•Defective piston ring, packing, valve
(•Check, repair)
•Clogging inside piping
(•Check, repair)
Cylinder lacks holding power •Tighten
•Leakage of oil from piping, hose
(•Replace)
•Defective piston ring, packing
(•Check, repair)
•Defective piston valve
(•Check, repair)
•Defective valve spool
(•Check, repair)
•Defective safety valve, suction valve
Oil pressure does not rise (•Repair)

•Clogging inside piping
(•Check, adjust)
•Defective adjustment of relief valve
MAINTENANCE 6
LUBRICATING
1. Lower the ripper to the ground and stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.
6-7
(1) Ripper cylinder foot pin (1 place)
(2) Ripper cylinder rod end pin (1 place)
(3) Link pin (8 places)
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
1. Stop the machine on level ground.
Set the blade perpendicular and lower it the ground, lower the ripper to the ground, then stop the engine.
2. For details of checking the oil level in the hydraulic tank, see “CHECK OIL LEVEL IN HYDRAULIC TANK, ADD
OIL (4-47)“.
SPECIFICATIONS 6
D65EX: Power tilt-dozer with ROPS guard, cab and air conditioner
D65WX: Semi-U dozer with ROPS guard, cab and air conditioner
Item Unit D65EX-15 D65WX-15

Operating weight
kg 21,400 22,820
(not including operator)
Weight of ripper as
kg 1,610 1,610
individual part
A Overall length mm 6,480 6,665
No. of shanks 3 3
6-8
ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT
AIR SUSPENSION SEAT 6
ADJUSTMENT 6
WARNING
NOTICE
There is danger of damage to the air compressor, so do not keep lever (3) operated continuously for more
than 1 minute.
Adjustments (C), (D), and (I) use the air compressor built into the seat, so turn the engine starting switch to the ON
position when carrying out the adjustment.
(B) Adjusting seat angle
Move lever (2) up, move the seat cushion at the front up or
down to set to the desired position, then release the lever.
Amount of adjustment
Forward tilt: 3 degrees
Rear tilt: 11 degrees
(C) Setting seat for operator's weight
To protect the operator, it is necessary to adjust the suspension

to match the weight of the operator.
Pull lever (3) up fully (pull it until a click can be felt). When the lever is released, the weight adjustment is carried
out automatically. To ensure that the weight adjustment is carried out correctly, the operator should sit in the nor-
mal operating position when operating the lever. If the operator raises his body from the seat or changes the
amount of weight applied to the seat during adjustment, the air in the suspension may be discharged.
If lever (3) is pulled lightly, the weight adjustment starts, but always pull the lever up fully (pull it until a click is felt)
before releasing it.
When operators change shifts, first release the air, then carry out the above operation.
6-9
AIR SUSPENSION SEAT ATTACHMENTS, OPTIONS
If the operator raises his body from the seat or changes the amount of weight applied to the seat during adjust-
ment, the air in the suspension may be discharged.
Amount of adjustment: 80 mm
After the automatic weight adjustment is carried out, the seat height is at the lowest point in the adjustment range.
Adjust the seat to the appropriate height.
(D) Seat height adjustment
The seat height adjustment uses an air system, and it can be adjusted steplessly.
When adjusting the height, pull lever (3) up fully or push it down fully (when pulling it up, pull it until a click is felt).
When the seat is set at the desired height, release the lever. If the lever is kept pulled up, the position where the
seat does not rise any further is the maximum height. When the seat reaches the maximum height, the suspen-
sion automatically goes down slightly to secure the amount of movement of the lever.
To prevent the suspension from reaching the bottom, do not set to the seat height below the adjustment range.
(E) Fore-and-aft adjustment of seat cushion
Operate lever (4) up, set the seat cushion to the desired position, then release the lever.
Fore-and-aft adjustment: 60 mm
(F) Adjusting reclining angle
Move lever (5) up and move the backrest to the front or rear.
Push your back against the backrest when carrying out this adjustment. If your back is not pressing against the
backrest, the backrest may suddenly spring forward.
Amount of adjustment
Forward tilt: 20 degrees (over 20 degrees is free)
Rear tilt: 60 degrees
REMARK
The seat can be reclined more when the seat is pushed to the front. The amount of reclining decreases as the seat
is pushed back, so when moving the seat back, return the seatback to the upright position.
NOTICE
If the seat back is reclined too far, the seat back may hit the rear glass, so use it in a position where it does
not contact the glass.
(G) Adjusting headrest angle
Rotate the backrest to the front or rear and set to the desired angle.
Amount of adjustment: 38 degrees
6-10
ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT
(H) Adjusting headrest height
Move the headrest up or down and set to the desired height.
Amount of adjustment: 100 mm
(I) Lumbar support
Operate switch (6) to give a suitable tension to the lumbar region.
When + is pressed: Tension becomes stronger
When - is pressed: Tension becomes weaker
Adjust the backrest to the desired curve.
6-11
DELUXE SEAT ATTACHMENTS, OPTIONS
DELUXE SEAT 6
(Rotating seat)
ADJUSTMENT 6
WARNING
(B) Weight and height adjustment of seat
q Turn knob (2) under the seat so that weight adjustment

indicator (3) displays the green range. The height can be
adjusted by turning the knob (2) while the green range is
displayed.
q Turn the knob clockwise to raise the seat and turn the knob
counterclockwise to lower the seat.
Height adjustment range: stepless, 75 mm
Weight adjustment range: 50 to 130 kg
(C) Adjust reclining angle
REMARK
When the seat is pushed forward, the available reclining angle
becomes greater; when the seat is pushed back, the available
reclining angle becomes smaller. When moving the backrest,
return the backrest to its original position before moving the
seat.
Pull up lever (4), set the seatback to a position where it is easy

to operate, then release the lever.
6-12
ATTACHMENTS, OPTIONS DELUXE SEAT
(D) Adjusting direction of seat
NOTICE
Depending on the position of the seat, when changing the
direction of the seat, it may contact the console or other
parts.
Be extremely careful.
Pull up lever (5) to unlock the seat. The seat can then be
turned 15° to the right.
After changing the direction of the seat, return the lever

securely to lock the seat.
q Change the direction of the seat to the right for the ease of
operation of the ripper.
6-13
HEADREST ATTACHMENTS, OPTIONS
HEADREST 6
Removal of headrest
Pull up the headrest.
REMARK
The headrest cannot be fixed to halfway.
6-14
ATTACHMENTS, OPTIONS EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT 6

Equipping the fire extinguisher and the first-aid kit at the illustrated position needs brackets (if equipped).
The fire extinguisher and the first-aid kit can be installed to the positions shown in the following illustration.
(1) First Aid Kit
(2) Fire Extinguisher
For information on parts which are required to install these

items on the machine, call your Komatsu distributor.
6-15
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT ATTACHMENTS, OPTIONS
6-16
INDEX
17
INDEX
7-2
INDEX
INDEX
1
<A> GUIDE TO MAINTENANCE .................................. 4-2

ADJUSTING POSTURE OF WORK EQUIPMENT.. 3-
90
AIR CONDITIONER, HANDLING ........................ 3-48 <H>
GENERAL LOCATIONS AND FUNCTION OF HANDLING HYDRAULIC RIPPER ........................ 6-3
CONTROL PANEL .......................................... 3-48 EXPLANATION OF COMPONENTS ................ 6-4
METHOD OF OPERATION............................. 3-50 GENERAL VIEW............................................... 6-3
PRECAUTIONS WHEN USING ...................... 3-51 MAINTENANCE ................................................ 6-7
AIR SUSPENSION SEAT ...................................... 6-9 OPERATION ..................................................... 6-5
ASHTRAY ............................................................ 3-46 SPECIFICATIONS ............................................ 6-8
TROUBLESHOOTING ...................................... 6-7
HANDLING HYDRAULIC SYSTEM....................... 4-9
<B> HANDLING OIL, FUEL, COOLANT, AND
BEFORE READING THIS MANUAL...................... 1-2 PERFORMING OIL CLINIC .............................. 4-5
BETWEEN FORWARD AND REVERSE ............. 3-83 HEADREST ......................................................... 6-14
<C> <I>
CAR STEREO, HANDLING ................................. 3-48 IMPORTANT SAFETY INFORMATION .......... 1-4,2-2
CHECK AFTER FINISHING WORK .................... 3-95 INTENDED USE .................................................... 1-8
CHECK BEFORE STARTING ENGINE, ADJUST... 3- BREAKING-IN THE NEW MACHINE.............. 1-10
53 GENERAL VIEW AND DIRECTIONS OF
CIRCUIT BREAKER ............................................ 3-41 MACHINE.......................................................... 1-8
COLD WEATHER OPERATION ........................ 3-108 USE OF MACHINE ........................................... 1-8
AFTER COLD WEATHER............................. 3-109 VISIBILITY FROM OPERATORSSEAT' ........... 1-9
AFTER COMPLETION OF WORK................ 3-109
PRECAUTIONS FOR LOW TEMPER........... 3-108
CONTROL LEVERS AND PEDALS..................... 3-33 <L>
CUP HOLDER...................................................... 3-47 LIFTING MACHINE ........................................... 3-105
LOADING, UNLOADING WORK ....................... 3-102
LOCATION OF PLATES, TABLE TO ENTER SERIAL
<D> NO. AND DISTRIBUTOR................................ 1-11
DELUXE SEAT .................................................... 6-12 ADDITIONAL EPA NAMEPLATE.................... 1-12
DOOR - OPEN LOCK .......................................... 3-44 ENGINE SERIAL NO. PLATE POSITION....... 1-11
DOOR POCKET................................................... 3-45 PRODUCT IDENTIFICATION NUMBER (PIN)/
MACHINE SERIAL NO. PLATE ...................... 1-11
SERVICE METER POSITION......................... 1-12
<E> TABLE TO ENTER SERIAL NO. AND
ELECTRIC POWER TAKE-OUT ADAPTER........ 3-43 DISTRIBUTOR................................................ 1-13
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID LOCKING............................................................. 3-96
KIT ................................................................... 6-15 LONG-TERM STORAGE................................... 3-110
EXPLANATION OF COMPONENTS ..................... 3-6 AFTER STORAGE........................................ 3-110
BEFORE STORAGE..................................... 3-110
DURING STORAGE ..................................... 3-110
<F>
FRONT PANEL ...................................................... 3-6
FUSE.................................................................... 3-41 <M>
FUSIBLE LINK ..................................................... 3-43 MACHINE OPERATION ...................................... 3-77
MAINTENANCE SCHEDULE CHART................. 4-19
MAINTENANCE SCHEDULE CHART ............ 4-19
<G>
GENERAL PRECAUTIONS ................................... 6-2
PRECAUTIONS RELATED TO SAFETY .......... 6-2 <O>
GENERAL VIEW.................................................... 3-2 OPENING AND CLOSING ENGINE SIDE COVER 3-
GENERAL VIEW OF CO ....................................... 3-3 46
GENERAL VIEW OF MACHINE ............................ 3-2 OPERATION........................................................ 3-53
-1
INDEX
OPERATIONS AND CHECKS AFTER STARTING <T>

ENGINE ...........................................................3-73 TIPS FOR LONGER UND ................................... 3-96
OUTLINE OF SERVICE .........................................4-5 TOOL BOX .......................................................... 3-47
TORQUE LIST ..................................................... 4-16
TRANSPORTATION.......................................... 3-100
<P> TRANSPORTATION MEANS ............................ 3-100
PARKING MACHINE ...........................................3-94 TRAVELING ON ROADS .................................. 3-107
PERIODIC REPLACEMENT OF SAFETY CRITICAL TROUBLESHOOTING....................................... 3-111
PARTS.............................................................4-17 AFTER RUNNING OUT OF FUEL ................ 3-111
PRECAUTIONS COMMON TO OPERATION AND IF BATTERY IS DISCHARGED .................... 3-113
MAINTENANCE ..............................................2-10 METHOD OF TOWING MACHINE ............... 3-112
PRECAUTIONS DURING OPERATION ..............2-17 OTHER TROUBLE........................................ 3-117
PRECAUTIONS FOR MACHINE .........................2-29
PRECAUTIONS FOR MAINTENANCE ...............2-23
PRECAUTIONS FOR OPERATION ....................3-86 <V>
PRECAUTIONS WHEN REMOVING ROPS .....3-101 Vibration levels ...................................................... 1-5
PRECAUTIONS WHEN REMOVING WORK
EQUIPMENT .................................................3-100
<W>
WEAR PART LIST ............................................... 4-10
<R> WEAR PARTS LIST ............................................ 4-10
RECOMMENDED FUEL, COOLANT, AND WORK POSSIBLE USING BULLDOZER ............ 3-88
LUBRICANT ....................................................4-12
RECOMMENDED BRANDS, RECOMMENDED
QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL...............................4-15
USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE4-13
RELATING TO ELECTRIC SYSTEM.....................4-8
REMOVING CAB ...............................................3-100
<S>
SAFETY CRITICAL PARTS .................................4-17
SAFETY LABELS...................................................2-4
POSITION FOR ATTACHING SAFETY LABELS2-
5
SAFETY LABELS ..............................................2-5
SASH GLASS INTERMEDIATE LOCK ................3-45
SERVICE PROCEDURE .....................................4-21
CHECK BEFORE STARTING .........................4-43
EVERY 1000 HOURS SERVICE.....................4-57
EVERY 250 HOURS SERVICE.......................4-44
EVERY 50 HOURS SERVICE.........................4-43
EVERY 500 HOURS SERVICE.......................4-52
WHEN REQUIRED..........................................4-21
SHIFTING GEARS...............................................3-79
SHOVEL HOLDER...............................................3-47
SPECIFICATIONS .................................................5-2
STANDARD TIGHTENING TORQUES FOR BOLTS
AND NUTS ......................................................4-16
STARTING ENGINE ............................................3-68
STEERING MACHINE .........................................3-85
STOPPING ENGINE............................................3-75
SWITCHES ..........................................................3-29
-2
COLOPHON
18
COLOPHON
D65EX-15, D65PX-15, D65WX-15 GALEO BULLDOZER

Form No. EEAM024400
© 2006 KOMATSU
All Rights Reserved
Printed in Belgium 01-06
8-2

D65EX D65PX: Operation & Maintenance Manual

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D65EX D65PX: Operation & Maintenance Manual

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Operation & EEAM024400

BEFORE READING THIS MANUAL 1

Operation and Maintenance Manual Storing Place

For a machine with a cab, a pocket is provided on the inside of

For a machine with a ROPS canopy, a pocket is provided at the

IMPORTANT SAFETY INFORMATION 1

REMARKS This word is used for information that is useful to know.

Noise emission levels 1

q Sound pressure level at the operator's station, measured

q Sound power level emitted by the machine, measured

q If equipped with air suspension seat

q If equipped with mechanical suspension seat

(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)

(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion

Guide to Reduce Vibration Levels on Machine 1

1. Use the correct equipment and attachments.

2. Maintain the machine according to this manual

q Brake and steering systems

q Controls, hydraulic system and linkages

q Fill any ditches and holes

q Wear seat belt

q Inspect and maintain the seat suspension and adjustment mechanisms

q Drive around obstacles and rough terrain conditions

q Slow down when it is necessary to go over rough terrain

q Make the curve radius of traveling path as large as possible

q Travel at low speed when traveling around sharp curves

7. Minimize vibrations for long work cycle or long distance traveling

q Transport machines long distances between worksites

q Provide breaks to reduce long periods of sitting in the same posture

q Do not jump down from the cab or machine

q Do not repeatedly handle and lift loads.

q Cutting into hard or frozen ground or ditching

q Felling trees, removing stumps

GENERAL VIEW AND DIRECTIONS OF MACHINE 1

(1) Blade (7) Sprocket

(A) Front (C) Left

VISIBILITY FROM OPERATOR'S SEAT 1

12M CIRCUMFERENCE VISIBILITY 1

BREAKING-IN THE NEW MACHINE 1

q Idle the engine for 5 minutes after starting it up.

q Avoid operation with heavy loads or at high speeds.

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO.

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1

The design of the nameplate differs according to the territory.

ENGINE SERIAL NO. PLATE POSITION 1

ADDITIONAL EPA NAMEPLATE 1

EPA: Environmental Protection Agency, U.S.A.

SERVICE METER POSITION 1

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1

Machine serial No.

Engine serial No.

Product Identification Number

Manufacturers name: KOMATSU LTD.

Service personnel for your

MACHINE SERIAL NUMBER PLATE 1

Product Identification Number

IMPORTANT SAFETY INFORMATION ............................................................................................................... 1-4

INTENDED USE ................................................................................................................................................... 1-8

SAFETY LABELS................................................................................................................................................. 2-4

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ............................................................... 2-10

PRECAUTIONS DURING OPERATION ............................................................................................................ 2-17

PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-23

PRECAUTIONS FOR MACHINE........................................................................................................................ 2-29